Crown Forklift ESR4500 Series Parts Manual 812704-006

Parts Manual

ESR4500 Series Printed in Germany ● Revision Level D Order Number: 812704-006

This master manual is subject to continual updates.

It is meant exclusively for businesses authorized by CROWN. It is not permitted to pass on the contents or copies thereof to third parties.

CROWN Gabelstapler GmbH & Co. KG - European Headquarter Moosacher Str. 52 80809 Munich Germany Phone +49 (0)89 93 00 2 - 0 Fax +49 (0)89 93 00 2 - 133

All rights reserved under international and Pan-American Copyright Agreement.

Copyright 2005 CROWN Equipment Corporation

TABLE OF CONTENTS

Printed in Germany

1

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Printed in Germany

M1.0-0000-0002 M1.0-0000-0002 2

TABLE OF CONTENT Table of Content ITD – INTRODUCTION

PAGE

SERIAL NR. CUT

REV.

SERIAL NR. CUT

REV.

General ................................................................................. 7

SECTION 1 – COVERS

PAGE

Covers................................................................................... 12, 14 ..................................................... 02 Rev. 11/05 Covers................................................................................... 16 ......................... 5A204796 ................. 01 Rev. 05/05 Covers................................................................................... 16A ....................... 5A204798 ................. 02 Rev. 11/05 Skid Block and Wear Strips .................................................. 18 ......................... 5A204488 Skid Block and Wear Strips .................................................. 18A ....................... 5A204490 ................. 01 Rev. 11/05 Reach Carriage ..................................................................... 20 ........................................................... 01 Rev. 05/05 Load Wheel ........................................................................... 22 ........................................................... 01 Rev. 11/05 Battery Lock .......................................................................... 24 ........................................................... 01 Rev. 05/05 Battery Reach Out ................................................................ 26 ......................... 5A203866 Battery Reach Out ................................................................ 26A ....................... 5A203868 ................. 02 Rev. 11/05 Seat & Pan ............................................................................ 28 ........................................................... 01 Rev. 05/05 Seat ....................................................................................... 30 ......................... 5A203880 Seat ....................................................................................... 30A ....................... 5A203882 ................. 01 Rev. 05/05 Rear Mirror ............................................................................ 32 Guide Wheels ........................................................................ 34 Overhead Guard .................................................................... 36 ........................................................... 01 Rev. 05/05 Accessories .......................................................................... 38 ........................................................... 02 Rev. 11/05

SECTION 2 – HYDRAULIC PART

PAGE

SERIAL NR. CUT

REV.

Tube-/Hose Layout ................................................................ 42 ........................................................... 02 Rev. 11/05 Hydraulic Tank ....................................................................... 44 ........................................................... 01 Rev. 05/05 Hydraulic TT Mast ................................................................. 46, 48 ................... 5A203818 Hydraulic TT Mast ................................................................. 46A ....................... 5A203820 ................. 01 Rev. 05/05 Valve Block ........................................................................... 50 Pump ..................................................................................... 52 Pump Motor and Pump ......................................................... 54 ........................................................... 01 Rev. 05/05 Pump Motor ........................................................................... 56 ........................................................... 01 Rev. 05/05

SECTION 3 – DRIVE UNIT

PAGE

SERIAL NR. CUT

REV.

Drive Unit .............................................................................. 60 ......................... 5A204000 Drive Unit .............................................................................. 60A ....................... 5A204002 ................. 01 Rev. 05/05 Drive Unit .............................................................................. 60B ....................... 5A204798 ................. 02 Rev. 11/05 Gearbox ................................................................................. 62 ......................... 5A204796 Gearbox ................................................................................. 62A ....................... 5A204798 ................. 01 Rev. 11/05 Drive Motor ........................................................................... 64 ........................................................... 01 Rev. 05/05

SECTION 4 – ELECTRICAL

PAGE

SERIAL NR. CUT

REV.

Electrical Compartment ........................................................ 68, 70 ................... 5A204796 ................. 01 Rev. 05/05 Electrical Compartment ........................................................ 68A, 70A .............. 5A204798 ................. 02 Rev. 11/05 Contactor .............................................................................. 72 Reach Slowdown ................................................................... 74 HGTS Lift Speed Reduction .................................................. 76 ......................... 5A203818 HGTS Lift Speed Reduction .................................................. 76A ....................... 5A203820 ................. 01 Rev. 05/05 Height Encoder ..................................................................... 78 ......................... 5A203818 Height Encoder ..................................................................... 78A ....................... 5A203820 ................. 02 Rev. 11/05 Mast Wiring ........................................................................... 80, 82 ..................................................... 01 Rev. 05/05 Joystick and Emergency Disconnector Switch ..................... 84 ......................... 5A204796 ................. 01 Rev. 05/05 Joystick and Emergency Disconnector Switch ..................... 84A, 86A .............. 5A204798 ................. 02 Rev. 11/05 Direction Switch/Horn Button ................................................ 88 ......................... 5A204796 Direction Switch/Horn Button ................................................ 88A ....................... 5A204798 ................. 01 Rev. 11/05 Floorplate .............................................................................. 90 Accelerator ............................................................................ 92 ........................................................... 01 Rev. 05/05 MP-ESR4500-GB 06/04 • Printed in Germany

MP-IDX-2140

02 REV. 11/05 M1.0-0000-0003 33

TABLE DES MATIÈRES Interrupteur de sécurité ......................................................... 94 ........................................................... 01 Rev. 05/05 DC/DC Redresseur ............................................................... 96 ........................................................... 01 Rev. 05/05 Tableau de commande .......................................................... 98 ........................................................... 01 Rev. 05/05 Tableau d'affichage ................................................................ 100 ....................... 5A204796 ................. 01 Rev. 05/05 Tableau d'affichage ................................................................ 100A ..................... 5A204798 ................. 02 Rev. 11/05 Lamp d'avertissement ........................................................... 102 ......................................................... 01 Rev. 11/05 Pares de marche ................................................................... 104 ......................................................... 01 Rev. 05/05 Pares de traval ...................................................................... 106 Signal sonore de marche-arriére .......................................... 108 ......................................................... 01 Rev. 05/05 Connexion et partie de fixation ............................................. 110 Klaxon ................................................................................... 112 System de refroidir ............................................................... 114 ......................................................... 02 Rev. 11/05

CHAPITRE 5 – SYSTEME DE FREINAGE

PAGE

COUPURE NR. SÉRIE REV.

Circuit de freinage ................................................................. 118 Pédale de frein ...................................................................... 120 Frein moteur .......................................................................... 122 Frein roues porteuses ........................................................... 124

CHAPITRE 6 – DIRECTION

PAGE

COUPURE NR. SÉRIE REV.

Moteur de direction ............................................................... 128 ....................... 5A204796 Moteur de direction ............................................................... 128A ..................... 5A204798 ................. 01 Rev. 11/05 Colonne de direction ............................................................. 130 ......................................................... 01 Rev. 05/05

CHAPITRE 7 – MÂT

PAGE

COUPURE NR. SÉRIE REV.

Mât TT 1.4t/1.6t ..................................................................... 134, 136 ............... 5A203818 Mât TT 1.4t/1.6t ..................................................................... 134A, 136A .......... 5A203820 ................. 01 Rev. 05/05 Mât TT 2.0t ............................................................................ 138, 140 ............... 5A203818 Mât TT 2.0t ............................................................................ 138A, 140A .......... 5A203820 ................. 01 Rev. 05/05 Chaîne de levage mât TT ...................................................... 142, 144 Inclinaison/déplacement latéral ............................................. 146, 148 Inclinaison/déplacement latéral-hydraulique ......................... 150, 152, 154 ......................................... 02 Rev. 11/05 Armotissement de levée ........................................................ 156 ......................................................... 01 Rev. 05/05 Dent de fourche ..................................................................... 158 ......................................................... 01 Rev. 05/05 Butée de charge .................................................................... 160 Poulies de guidage ................................................................ 162

CHAPITRE 8 – VÉRINS

PAGE

COUPURE NR. SÉRIE REV.

Vérin de levée 1.4t/1.6t ......................................................... 166 ....................... 5A203818 Vérin de levée 1.4t/1.6t ......................................................... 166A ..................... 5A203820 ................. 01 Rev. 05/05 Vérin de levée 2.0t ................................................................. 168 ....................... 5A203818 Vérin de levée 2.0t ................................................................. 168A ..................... 5A203820 ................. 01 Rev. 05/05 Vérin de levée libre 1.4t/1.6t .................................................. 170 Vérin de levée libre 2.0t ......................................................... 172 Vérin de rétration ................................................................... 174

CHAPITRE 9 – CABIN/PLATE - FORME

PAGE

COUPURE NR. SÉRIE REV.

Cabine chambres froides ...................................................... 178 ......................................................... 02 Rev. 02/06

CHAPITRE 10 – AUTRES INFORMATIONS

SPAGE

COUPURE NR. SÉRIE REV.

Autocolants et ètiquettes ....................................................... 182 ......................................................... 02 Rev. 11/05

MP-IDX-2140

MP-ESR4500-FR 06/04 • Printed in Germany

03 REV. 02/06

4 4M1.0-0000-0004

INTRODUCTION

Printed in Germany

5

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Printed in Germany

M1.0-0000-0006 M1.0-0000-0006 6

INTRODUCTION Important customer information

Ordering Spare Parts

To ensure the safety of the truck, you, the customer, must only carry out maintenance and repairs as stipulated in the operator manual.

Spare parts can be ordered by quoting: ●

The truck specification number

Any additional work must be performed by Crown authorised service technicians. Authorised service technicians have the required expertise and up-to-date service information.

●

The truck model number

●

The truck serial number

If you wish to have your own technicians trained, please contact Crown for relevant training courses.

Subsequent Attachments and Modifications made to the Truck DANGER! Any proposed modification which would alter the original condition of the truck when delivered, must first be assessed and approved in writing by Crown Gabelstapler GmbH. ●

The net weight and position of attachments may considerably affect the capacity and other truck characteristics.

●

Changing the electrical system or adding electrically operated components may result in operating faults.

This information can be found on the truck's data plate.

Only if this information is provided can the order be processed quickly, correctly and reliably.

Please refer to the Technical Specifications Sheet for the utilisable loads, technical data and dimensions for this series. Brochures can be obtained from your CROWN dealer or from the following address:

CROWN Gabelstapler GmbH & CoKG Moosacher Str. 52 80809 Munich GERMANY Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 oder 133

Modifications which have not been assessed may result in fatal accidents!

MP-ESR4500-GB 06/04 • Printed in Germany

M/P-ITD-2140

M1.0-0000-0007 77

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Printed in Germany

8

PARTS

Printed in Germany

9

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Printed in Germany

10M1.0-0000-00010

SECTION 1

Printed in Germany

11

COVERS Part 1-3

2 3 5 4 6 1

7

8

5

5 7 5 14

9 5 10 11

13

10

12

11

MP-2140-063 MP-1.1-2140

12M1.0-0000-00012

MP-ESR4500-GB 06/04 • Printed in Germany

COVERS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 791764-003 .............................. Grab Handle ............................................................................................ 1 2 ..................... 813005-001 .............................. Spacer (5mm) ......................................................................................... 1 3 ..................... 813005-002 .............................. Spacer (2mm) ......................................................................................... 1 4 ..................... 050067-024 .............................. Screw ...................................................................................................... 1 5 ..................... 050068-003 .............................. Nut .......................................................................................................... 6 6 ..................... 806686-002 .............................. Corner Cover .......................................................................................... 1 7 ..................... 050071-035 .............................. Screw ...................................................................................................... 2 8 ..................... 815013 ..................................... Display Overlay ...................................................................................... 1 807053-002 .............................. Insert ...................................................................................................... 2 796164 ..................................... Display Overlay (Drive in Racking) ........................................................ 1 9* .................... 806687 ..................................... Head Rest ............................................................................................... 1 10* ................... 051068-003 .............................. Clip .......................................................................................................... 2 11* ................... 050004-020 .............................. Screw ...................................................................................................... 4 12 .................... 050068-004 .............................. Nut .......................................................................................................... 1 13 .................... 806931 ..................................... Leg Pad ................................................................................................... 1 053050-012 .............................. Adhesive Tape ......................................................................................... AR 14 .................... 812363 ..................................... Harness Cover ....................................................................................... 1

* ..................... 807352 ..................................... Head Rest Assembly (included 9 - 11) ................................................... 1

Not illustrated 796166 ..................................... Switch Cover (Drive in Racking) ............................................................ 2 050071-012 .............................. Screw (Drive in Racking) ........................................................................ 4 796708 ..................................... Headrest (Drive in Racking) ................................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.1-2140

01 REV. 05/05

13

COVERS Part 2-3

2 1

3

4

5

7

8

6

12 17 8 19 13 18 15 16 11 10

14

9

MP-2140-064 MP-1.1-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05

14M1.0-0000-00014

COVERS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 815040 ..................................... Steering Wheel ........................................................................................ 1 2 ..................... 118917 ..................................... Spinner knob ........................................................................................... 1 3 ..................... 050010-021 .............................. Washer ................................................................................................... 1 4 ..................... 060016-019 .............................. Screw ...................................................................................................... 1 5 ..................... 050005-028 .............................. Screw ...................................................................................................... 1 6 ..................... 812138 ..................................... Steering Column Cover ........................................................................... 1 7 ..................... 050071-019 .............................. Screw ...................................................................................................... 2 8 ..................... 050071-020 .............................. Screw ...................................................................................................... 4 9 ..................... 812125 ..................................... Steering Column Cover ........................................................................... 1 10 .................... 812127 ..................................... Cover ...................................................................................................... 1 11 .................... 050003-010 .............................. Screw ...................................................................................................... 3 12 .................... 050008-001 .............................. Nut .......................................................................................................... 3 13 .................... 050003-014 .............................. Screw ...................................................................................................... 1 14 .................... 125502 ..................................... Pocket Storage ....................................................................................... 1 15 .................... 125503 ..................................... Mount Pocket .......................................................................................... 1 16 .................... 050005-060 .............................. Screw ...................................................................................................... 2 17 .................... 050068-002 .............................. Nut .......................................................................................................... 2 18 .................... 812364 ..................................... Tray ......................................................................................................... 1 19 .................... 050068-003 .............................. Nut .......................................................................................................... 4

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.1-2140

01 REV. 11/05

15

COVERS Part 3-3

5

4 4

3

1 3 2

6

6

4

7

9

8 12 11 4

10

13

16 14 16 14

15

15

14 17 16 MP-2140-062 MP-1.1-2140

16M1.0-0000-00016

MP-ESR4500-GB 06/04 • Printed in Germany

COVERS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ........................................................................ Instrumentation (see Section 4.9) ........................................................... 1 2* .................... 807098 ..................................... Armrest Moulding .................................................................................... 1 796489 ..................................... Armrest Moulding (6th Function Valve) ................................................... 1 3 ..................... 050009-020 .............................. Washer ................................................................................................... 2 4 ..................... 050071-035 .............................. Screw ...................................................................................................... 6 5* .................... 806689 ..................................... Armrest Pad ............................................................................................ 1 6* .................... 050067-012 .............................. Screw ...................................................................................................... 5 7 ........................................................................ Compartment Tray (see Section 4.1) ...................................................... 1 8 ..................... 806973 ..................................... Hand Guard ............................................................................................ 1 796024 ..................................... Hand Guard (Drive in Racking) ............................................................... 1 9 ..................... 050068-003 .............................. Nut .......................................................................................................... 3 10 .................... 812247 ..................................... Plate ........................................................................................................ 1 814887 ..................................... Plate (Drive in Racking) .......................................................................... 1 11 .................... 807053-002 .............................. Insert ...................................................................................................... 3 12 .................... 050008-030 .............................. Nut .......................................................................................................... 3 13 .................... 816196 ..................................... Cover ...................................................................................................... 1 806499 ..................................... Cover (Drive in Racking) ........................................................................ 1 14 .................... 052068-002 .............................. Spacer .................................................................................................... 4 15 .................... 816095 ..................................... Cable Clamp ........................................................................................... 2 807764 ..................................... Cable Clamp (Drive in Racking) .............................................................. 2 16 .................... 050008-008 .............................. Nut .......................................................................................................... 4 17 .................... 807765 ..................................... Cable Clamp (Drive in Racking) .............................................................. 2

* ..................... 806929 ..................................... Armrest Assembly (included 2, 5, 6/without 796489) .............................. 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.1-2140

01 REV. 05/05

17

COVERS Part 3-3

5

4 4

3

1 3 2

6

6

4

7

9

8 12 11 4

10

13

16 14 16 14

15

15

MP-2140-115 MP-1.1-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 11/05 M1.0-0000-00016 16A

COVERS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ........................................................................ Instrumentation (see Section 4.9) ........................................................... 1 2* .................... 807098 ..................................... Armrest Moulding .................................................................................... 1 816994 ..................................... Armrest Moulding (Dual-Axis Controls) ................................................... 1 796489 ..................................... Armrest Moulding (6th Function Valve) ................................................... 1 3 ..................... 050009-020 .............................. Washer ................................................................................................... 2 4 ..................... 050071-035 .............................. Screw ...................................................................................................... 6 5* .................... 806689 ..................................... Armrest Pad ............................................................................................ 1 6* .................... 050067-012 .............................. Screw ...................................................................................................... 5 7 ........................................................................ Compartment Tray (see Section 4.1) ...................................................... 1 8 ..................... 806973 ..................................... Hand Guard ............................................................................................ 1 796024 ..................................... Hand Guard (Drive in Racking) ............................................................... 1 9 ..................... 050068-003 .............................. Nut .......................................................................................................... 3 10 .................... 812247 ..................................... Plate ........................................................................................................ 1 814887 ..................................... Plate (Drive in Racking) .......................................................................... 1 11 .................... 807053-002 .............................. Insert ...................................................................................................... 3 12 .................... 050008-030 .............................. Nut .......................................................................................................... 3 13 .................... 816196 ..................................... Cover ...................................................................................................... 1 14 .................... 052068-002 .............................. Spacer .................................................................................................... 4 15 .................... 816095 ..................................... Cable Clamp ........................................................................................... 2 16 .................... 050008-008 .............................. Nut .......................................................................................................... 4

* ..................... 818543-001 .............................. Armrest Assembly (included 2, 5, 6/without 796489) .............................. 1 * ..................... 818543-002 .............................. Armrest Assembly (Dual-Axis Controls/included 2, 5, 6/without 796489) 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.1-2140

02 REV. 11/05

17A

SKID BLOCK AND WEAR STRIPS

Chassis

1

2 Chassis

4

3 6 5

MP-2140-029 MP-1.1-2140

18M1.0-0000-00018

MP-ESR4500-GB 06/04 • Printed in Germany

SKID BLOCK AND WEAR STRIPS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 790797-001 .............................. Block, Skid .............................................................................................. 2 2 ..................... 790798 ..................................... Screw ...................................................................................................... 2 3 ..................... 810637-*** ............................... Wear Strips (see Table) ........................................................................... 2 814895-*** ............................... Wear Strips (see Table/Freezer/Corrosion) ............................................. 2 4 ..................... 050003-043 .............................. Screw ...................................................................................................... 2 5 ..................... 050009-026 .............................. Washer ................................................................................................... 2 6 ..................... 050005-068 .............................. Screw ...................................................................................................... 2

Position 3

Load Wheel ∅ 285 mm

1,4t Leg Witdth 1285 mm

1,6t & 2,0t Leg Witdth 1285 mm

1,4t Leg Witdth 1425 & 1575 mm

1,6t & 2,0t Leg Witdth 1425 & 1575 mm

810637-001

810637-002

810637-004

810637-005

Load Wheel ∅ 330 mm

810637-003

810637-006 Tab019gb

Position 3 Freezer/Corrosion

Load Wheel ∅ 285 mm

1,4t Leg Witdth 1285 mm

1,6t & 2,0t Leg Witdth 1285 mm

1,4t Leg Witdth 1425 & 1575 mm

1,6t & 2,0t Leg Witdth 1425 & 1575 mm

814895-001

814895-002

814895-004

814895-005

Load Wheel ∅ 330 mm

814895-003

814895-006 Tab020gb

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.1-2140

19

SKID BLOCK AND WEAR STRIPS

Chassis

1

2 Chassis

4

3 6 5

MP-2140-029 MP-1.1-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 11/05 M1.0-0000-00018 18A

SKID BLOCK AND WEAR STRIPS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 790797-001 .............................. Block, Skid .............................................................................................. 2 2 ..................... 790798 ..................................... Screw ...................................................................................................... 2 3 ..................... 810637-*** ............................... Wear Strips (see Table) ........................................................................... 2 4 ..................... 050003-043 .............................. Screw ...................................................................................................... 2 5 ..................... 050009-026 .............................. Washer ................................................................................................... 2 6 ..................... 050005-068 .............................. Screw ...................................................................................................... 2

Position 3

Load Wheel ∅ 285 mm

1,4t Leg Witdth 1285 mm

1,6t & 2,0t Leg Witdth 1285 mm

1,4t Leg Witdth 1425 mm

1,6t & 2,0t Leg Witdth 1425 mm

1,4t Leg Witdth 1575 mm

1,6t & 2,0t Leg Witdth 1575 mm

810637-001

810637-002

810637-007

810637-008

810637-004

810637-005

Load Wheel ∅ 330 mm

810637-003

810637-009

810637-006 Tab026gb

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.1-2140

01 REV. 11/05

19A

REACH CARRIAGE 30

31

1

34

32

7

33

3

4 5

2 6 8

35 29

9

22 17 23

28 18 10

24

21

25

20

11

27

15 26 12 19

13 14

16 MP-2140-049

MP-1.2-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05

20M1.0-0000-00020

REACH CARRIAGE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 811174 ..................................... Reach Carriage (1285mm Leg Width) ..................................................... 1 812062 ..................................... Reach Carriage (1425mm Leg Width) ..................................................... 1 812067 ..................................... Reach Carriage (1575mm Leg Width) ..................................................... 1 2 ..................... 050078-008 .............................. Blind Rivet Nut ........................................................................................ 3 3 ..................... 811017 ..................................... Spacer .................................................................................................... 8 4 ..................... 811012 ..................................... Bracket ................................................................................................... 2 5 ..................... 810654-001 .............................. Roller ...................................................................................................... 2 6 ..................... 811011 ..................................... Pin ........................................................................................................... 2 7 ..................... 050008-034 .............................. Nut .......................................................................................................... 2 8 ..................... 050000-009 .............................. Roll Pin ................................................................................................... 2 9 ..................... 050067-037 .............................. Screw (for 1425mm and 1575mm Leg Width) ......................................... 4 050067-037 .............................. Screw (for 1285mm Leg Width) ............................................................... 3 050007-033 .............................. Screw (for 1285mm Leg Width) ............................................................... 1 10 .................... 050067-037 .............................. Screw ...................................................................................................... 4 11 .................... 811015 ..................................... Bracket ................................................................................................... 2 12 .................... 811014 ..................................... Sliding Pin ............................................................................................... 2 13 .................... 810654-001 .............................. Roller ...................................................................................................... 2 14 .................... 811011 ..................................... Pin ........................................................................................................... 2 15 .................... 050008-034 .............................. Nut .......................................................................................................... 2 16 .................... 050000-009 .............................. Roll Pin ................................................................................................... 2 17 .................... 050017-021 .............................. Screw ...................................................................................................... 1 050006-053 .............................. Screw ...................................................................................................... 1 18 .................... 050068-004 .............................. Nut .......................................................................................................... 2 19 .................... 811001-001 .............................. Carriage Roller ........................................................................................ 4 20 .................... 050067-049 .............................. Screw ...................................................................................................... 16 21 .................... 813160 ..................................... Grease Nipple ......................................................................................... 4 22 .................... 050068-007 .............................. Nut .......................................................................................................... 2 23 .................... 050008-076 .............................. Nut .......................................................................................................... 2 24 .................... 812129 ..................................... Pin ........................................................................................................... 2 25 .................... 810654-002 .............................. Roller ...................................................................................................... 2 26 .................... 814134 ..................................... Washer ................................................................................................... 2 27 .................... 050012-021 .............................. Retaining Ring ........................................................................................ 2 28 .................... 050006-037 .............................. Screw ...................................................................................................... 1 29 .................... 807525 ..................................... Clamp ...................................................................................................... 1 30 .................... 813695 ..................................... Cover ...................................................................................................... 1 31 .................... 050067-034 .............................. Screw ...................................................................................................... 4 32 .................... 060030-085 .............................. Shim ........................................................................................................ 10 33 .................... 810203 ..................................... Shim ........................................................................................................ 2 34 .................... 806886 ..................................... Plate ........................................................................................................ 2 35 .................... 050005-075 .............................. Screw ...................................................................................................... 4

811010 ..................................... Guide Rollers Assembly (included 4 - 8) ................................................ 2 811013 ..................................... Guide Rollers Assembly (included 11 - 16) ............................................. 2 812134 ..................................... Excentric Rollers Assembly (included 24 - 27) ....................................... 2

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.2-2140

01 REV. 05/05

21

LOAD WHEEL 17

15

18

14

Chassis

16

13

11

12 10 9

7 6 5

8

4 3 2 1

MP-2140-032 MP-1.5-2140

22M1.0-0000-00022

MP-ESR4500-GB 06/04 • Printed in Germany

LOAD WHEEL INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 810576-001 .............................. Load Wheel Assembly ∅ 285mm/1,4t ..................................................... 2 810602-001 .............................. Load Wheel Assembly ∅ 330mm/1,6t & 2,0t ........................................... 2 1 ........................... 807095 ..................................... Load Wheel Cap ................................................................................ 2 2 ........................... 050012-009 .............................. Circlip ................................................................................................ 2 3 ........................... 790520 ..................................... Washer .............................................................................................. 2 4* .......................... 050012-015 .............................. Circlip ................................................................................................ 2 5* .......................... 807655 ..................................... Washer .............................................................................................. 2 6* .......................... 790519 ..................................... Roller Bearing ................................................................................... 2 7* .......................... 810577 ..................................... Spacer ............................................................................................... 2 8* .......................... 810574-001 .............................. Load Wheel ∅ 285mm/1,4t ................................................................ 2 810583-001 .............................. Load Wheel ∅ 330mm/1,6t & 2,0t ...................................................... 2 9* .......................... 790517 ..................................... Needle Bearing .................................................................................. 2 10* ......................... 050012-051 .............................. Circlip ................................................................................................ 2 11 .......................... 050005-088 .............................. Screw ................................................................................................ 12 12 .......................... 810564 ..................................... Brake Assy (see Section 5.6) ........................................................... 1 13 .......................... 810382 ..................................... Stud Axle ........................................................................................... 2 14 .......................... 790528 ..................................... End Block .......................................................................................... 2 15 .......................... 050005-033 .............................. Screw ................................................................................................ 4 16 .......................... 793333 ..................................... Clip .................................................................................................... 4 17 .......................... 810598 ..................................... Brake Guard 1,4t ............................................................................... 2 810597 ..................................... Brake Guard 1,6t & 2,0t .................................................................... 2 18 .......................... 050071-020 .............................. Screw ................................................................................................ 4 * ........................... 810575-001 .............................. Loadwheel ∅ 285mm & Bearing 1,4t Assembly (inclusive 4-10) ..... 2 * ........................... 810601-001 .............................. Loadwheel ∅ 330mm & Bearing 1,6t &2,0t Assembly ....................... 2 (included 4-10)

Option:

Load Wheel ∅ 285mm for 1,6t & 2,0t only available out of Factory

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.5-2140

01 REV. 11/05

23

BATTERY LOCK

22

1

23 5 20

4 3 24

21 2 7 28 26 8

6

29

5

27 9 4 14 16

32 20

10

22 17 5

13

4

11 15

18 25

12

30 Chassis

19

11

Battery Latch

31 MP-2140-035 MP-1.6-2140

24M1.0-0000-00024

MP-ESR4500-GB 06/04 • Printed in Germany

BATTERY LOCK INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 807530-001 .............................. Battery Lock ............................................................................................ 1 1* .......................... 807531 ..................................... Lever ................................................................................................. 1 2* .......................... 807535 ..................................... Bearing .............................................................................................. 1 3* .......................... 051058-014 .............................. Bushing ............................................................................................. 1 4 ........................... 050073-004 .............................. Spring Nut ......................................................................................... 5 5 ........................... 050070-002 .............................. Screw ................................................................................................ 5 6* .......................... 807534 ..................................... Link .................................................................................................... 1 7* .......................... 050007-009 .............................. Screw ................................................................................................ 2 8* .......................... 050008-018 .............................. Nut ..................................................................................................... 2 9* .......................... 807536 ..................................... Bracket .............................................................................................. 1 10 .......................... 807542-001 .............................. Shim (1mm) ....................................................................................... 2 807542-002 .............................. Shim(0,6mm) ..................................................................................... 1 11 .......................... 050068-004 .............................. Nut ..................................................................................................... 4 12* ......................... 803310 ..................................... Actuator Roller .................................................................................. 1 13* ......................... 792991 ..................................... Microswitch ....................................................................................... 1 14* ......................... 050004-034 .............................. Screw ................................................................................................ 2 15* ......................... 807541 ..................................... Plate .................................................................................................. 1 16* ......................... 050009-002 .............................. Washer .............................................................................................. 2 17* ......................... 050008-008 .............................. Nut ..................................................................................................... 1 18* ......................... 793288 ..................................... Clip .................................................................................................... 1 19* ......................... 050003-013 .............................. Screw ................................................................................................ 1 20* ......................... 051058-005 .............................. Bushing ............................................................................................. 2 21* ......................... 807539 ..................................... Spring ................................................................................................ 1 22* ......................... 051058-015 .............................. Bushing ............................................................................................. 2 23* ......................... 807538 ..................................... Spring ................................................................................................ 1 24* ......................... 807537 ..................................... Spacer ............................................................................................... 1 25 .......................... 807786 ..................................... Bracket .............................................................................................. 1 26* ......................... 806827 ..................................... Shaft .................................................................................................. 1 27* ......................... 050000-069 .............................. Roll Pin .............................................................................................. 1 28* ......................... 806819 ..................................... Shaft .................................................................................................. 1 29* ......................... 050000-025 .............................. Roll Pin .............................................................................................. 1 30 .......................... 050071-036 .............................. Screw ................................................................................................ 1 31 .......................... 050008-024 .............................. Nut ..................................................................................................... 1 32 .......................... 050009-026 .............................. Washer .............................................................................................. AR

* ........................... 807540 ..................................... Battery Lock (inclusive 1-3,6-9,12-24,26-29) .................................... 1

only for Freezer/Corrosion 796158 ..................................... Bracket ................................................................................................... 1 793288 ..................................... Clip .......................................................................................................... 1 050003-015 .............................. Screw ...................................................................................................... 1 050008-008 .............................. Nut .......................................................................................................... 1 796159 ..................................... Bracket ................................................................................................... 1 794590-001 .............................. Resistor Assembly ................................................................................. 1 050004-042 .............................. Screw ...................................................................................................... 2 050008-011 .............................. Nut .......................................................................................................... 2 050004-008 .............................. Screw ...................................................................................................... 2

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.6-2140

01 REV. 05/05

25

BATTERY REACH OUT 47

3 45 46

39

2 1

18

6

6

31

5

5 34 36 35 39 41 42 10

16

4

11 12 17

32

8

10 15

24

44

19

20

13

43

40

33

8

37

7 14

38

7

9 22 9

21

23 25

24

26 30 27

28

29 MP-2140-046

MP-1.6-2140

26M1.0-0000-00026

MP-ESR4500-GB 06/04 • Printed in Germany

BATTERY REACH OUT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 807841 ..................................... Battery Cover extension (Battery 560Ah) ............................................... 1 807842 ..................................... Battery Cover extension (Battery 700Ah) ............................................... 1 810227 ..................................... Battery Cover extension (Battery 820Ah) ............................................... 1 2 ..................... 050071-035 .............................. Screw ...................................................................................................... 4 3 ..................... 050068-003 .............................. Nut .......................................................................................................... 4 4 ..................... 810338-001 .............................. Battery Support (Battery 420Ah) ............................................................ 1 810338-002 .............................. Battery Support (Battery 560Ah) ............................................................ 1 810338-003 .............................. Battery Support (Battery 700Ah) ............................................................ 1 810338-004 .............................. Battery Support (Battery 820Ah) ............................................................ 1 5 ..................... 807451 ..................................... Plate (1285/1425mm Leg Width, Trucks without Battery Rollers) ............ 4 808023 ..................................... Plate (1575mm Leg Width, Trucks without Battery Rollers) ..................... 4 6 ..................... 050003-051 .............................. Screw ...................................................................................................... 8 7 ..................... 807860-001 .............................. Skid Block (1285mm Leg Width) ............................................................. 4 807860-002 .............................. Skid Block (1425mm Leg Width) ............................................................. 4 807860-003 .............................. Skid Block (1575mm Leg Width) ............................................................. 4 8 ..................... 050005-025 .............................. Screw ...................................................................................................... 8 9 ..................... 806408 ..................................... Skid Bar .................................................................................................. 4 10 .................... 050007-017 .............................. Screw ...................................................................................................... 4 11 .................... 055058-002 .............................. Buffer ...................................................................................................... 2 12 .................... 807938 ..................................... Shim ........................................................................................................ 2 13 .................... 807937 ..................................... Spacer .................................................................................................... AR 14 .................... 050008-015 .............................. Nut .......................................................................................................... 4 15 .................... 796380 ..................................... Spacer Plate (only for 1575mm Leg Width) ............................................. 1 16 .................... 050006-027 .............................. Screw (only for 1575mm Leg Width) ....................................................... 1 17 .................... 050008-015 .............................. Nut (only for 1575mm Leg Width) ............................................................ 1 18 .................... 050003-052 .............................. Screw ...................................................................................................... 1 19 .................... 806349 ..................................... Shaft ........................................................................................................ 1 20 .................... 051058-013 .............................. Bushing ................................................................................................... 1 21 .................... 812908 ..................................... Latch ....................................................................................................... 1 22 .................... 808081 ..................................... Shim ........................................................................................................ 2 23 .................... 807864 ..................................... Washer ................................................................................................... 1 24 .................... 050068-005 .............................. Nut .......................................................................................................... 3 25 .................... 813281 ..................................... Cam ........................................................................................................ 1 26 .................... 808465 ..................................... Cam-Protection ....................................................................................... 1 27 .................... 813284 ..................................... Bracket (only for Battery 820Ah) ............................................................ 1 28 .................... 813279 ..................................... Pin ........................................................................................................... 1 29 .................... 050006-073 .............................. Screw (only for Battery 820Ah) ............................................................... 2 30 .................... 050068-007 .............................. Nut (only for Battery 820Ah) ................................................................... 2 31 .................... 050070-001 .............................. Screw ...................................................................................................... 2 32 .................... 810437 ..................................... Plate ........................................................................................................ 1 33 .................... 050068-004 .............................. Nut .......................................................................................................... 2 34 .................... 055058-006 .............................. Buffer ...................................................................................................... 2 35 .................... 807407 ..................................... Washer (only for Battery 420Ah & 1285mm Leg Width) .......................... 2 36 .................... 050068-006 .............................. Nut .......................................................................................................... 2 37 .................... 807939 ..................................... Pin ........................................................................................................... 1 38 .................... 806837 ..................................... Spring ..................................................................................................... 1 39 .................... 050003-050 .............................. Screw ...................................................................................................... 4 40 .................... 810428 ..................................... Clamp (only for Battery 420Ah & 560Ah) ................................................ 1 810432 ..................................... Clamp (only for Battery 700Ah & 820Ah) ................................................ 1 41 .................... 810429 ..................................... Bracket ................................................................................................... 1 42 .................... 810427-001 .............................. Clamp (LH/only for Battery 420Ah & 560Ah) .......................................... 1 810427-002 .............................. Clamp (RH/only for Battery 420Ah & 560Ah) .......................................... 1 810431-001 .............................. Clamp (LH/only for Battery 700Ah & 820Ah) .......................................... 1 810431-002 .............................. Clamp (RH/only for Battery 700Ah & 820Ah) .......................................... 1 43 .................... 810390 ..................................... Washer ................................................................................................... 1 44 .................... 810317 ..................................... Lever ....................................................................................................... 1 For Trucks with Battery Rollers 45 .................... 804207 ..................................... Roller ...................................................................................................... 6 46 .................... 804681 ..................................... Bearing Ball ............................................................................................. 12 47 .................... 804208 ..................................... Roller Axle .............................................................................................. 6 Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.6-2140

27

BATTERY REACH OUT 46

3 44 45

39

2 1

18

6

6

31

5

5 34 36 35 39 41 42 10

16

4

11 12 17

32 40

33

8 8

10 15

24 19

20

13

43

37

7 14

38

7

Serial number cut 5A203868 only for Index 41, 42 and 43

9 22 9

21

23 25

24

26 30 27

28

29 MP-2140-095

MP-1.6-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05 M1.0-0000-00026 26A

BATTERY REACH OUT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 807841 ..................................... Battery Cover extension (Battery 560Ah) ............................................... 1 807842 ..................................... Battery Cover extension (Battery 700Ah) ............................................... 1 810227 ..................................... Battery Cover extension (Battery 820Ah) ............................................... 1 2 ..................... 050071-035 .............................. Screw ...................................................................................................... 4 3 ..................... 050068-003 .............................. Nut .......................................................................................................... 4 4 ..................... 810338-001 .............................. Battery Support (Battery 420Ah) ............................................................ 1 810338-002 .............................. Battery Support (Battery 560Ah) ............................................................ 1 810338-003 .............................. Battery Support (Battery 700Ah) ............................................................ 1 810338-004 .............................. Battery Support (Battery 820Ah) ............................................................ 1 5 ..................... 807451 ..................................... Plate (1285/1425mm Leg Width, Trucks without Battery Rollers) ............ 4 808023 ..................................... Plate (1575mm Leg Width, Trucks without Battery Rollers) ..................... 4 6 ..................... 050003-051 .............................. Screw ...................................................................................................... 8 7 ..................... 807860-001 .............................. Skid Block (1285mm Leg Width) ............................................................. 4 807860-002 .............................. Skid Block (1425mm Leg Width) ............................................................. 4 807860-003 .............................. Skid Block (1575mm Leg Width) ............................................................. 4 8 ..................... 050005-025 .............................. Screw ...................................................................................................... 8 9 ..................... 806408 ..................................... Skid Bar .................................................................................................. 4 10 .................... 050007-017 .............................. Screw ...................................................................................................... 4 11 .................... 055058-002 .............................. Buffer ...................................................................................................... 2 12 .................... 807938 ..................................... Shim ........................................................................................................ 2 13 .................... 807937 ..................................... Spacer .................................................................................................... AR 14 .................... 050008-015 .............................. Nut .......................................................................................................... 4 15 .................... 796380 ..................................... Spacer Plate (only for 1575mm Leg Width) ............................................. 1 16 .................... 050006-027 .............................. Screw (only for 1575mm Leg Width) ....................................................... 1 17 .................... 050008-015 .............................. Nut (only for 1575mm Leg Width) ............................................................ 1 18 .................... 050003-052 .............................. Screw ...................................................................................................... 1 19 .................... 806349 ..................................... Shaft ........................................................................................................ 1 20 .................... 051058-013 .............................. Bushing ................................................................................................... 1 21 .................... 812908 ..................................... Latch ....................................................................................................... 1 22 .................... 808081 ..................................... Shim ........................................................................................................ 2 23 .................... 807864 ..................................... Washer ................................................................................................... 1 24 .................... 050068-005 .............................. Nut .......................................................................................................... 3 25 .................... 813281 ..................................... Cam ........................................................................................................ 1 26 .................... 808465 ..................................... Cam-Protection ....................................................................................... 1 27 .................... 813284 ..................................... Bracket (only for Battery 820Ah) ............................................................ 1 28 .................... 813279 ..................................... Pin ........................................................................................................... 1 29 .................... 050006-073 .............................. Screw (only for Battery 820Ah) ............................................................... 2 30 .................... 050068-007 .............................. Nut (only for Battery 820Ah) ................................................................... 2 31 .................... 050070-001 .............................. Screw ...................................................................................................... 2 32 .................... 810437 ..................................... Plate ........................................................................................................ 1 33 .................... 050068-004 .............................. Nut .......................................................................................................... 2 34 .................... 055058-006 .............................. Buffer ...................................................................................................... 2 35 .................... 807407 ..................................... Washer (only for Battery 420Ah & 1285mm Leg Width) .......................... 2 36 .................... 050068-004 .............................. Nut .......................................................................................................... 2 37 .................... 807939 ..................................... Pin ........................................................................................................... 1 38 .................... 806837 ..................................... Spring ..................................................................................................... 1 39 .................... 050003-050 .............................. Screw ...................................................................................................... 4 40 .................... 810428 ..................................... Clamp (only for Battery 420Ah & 560Ah) ................................................ 1 816085 ..................................... Clamp (only for Battery 700Ah & 820Ah) ................................................ 1 41 .................... 814922 ..................................... Bracket ................................................................................................... 1 42 .................... 816086-001 .............................. Clamp (LH/only for Battery 420Ah & 560Ah) .......................................... 1 816086-002 .............................. Clamp (RH/only for Battery 420Ah & 560Ah) .......................................... 1 816026-001 .............................. Clamp (LH/only for Battery 700Ah & 820Ah) .......................................... 1 816026-002 .............................. Clamp (RH/only for Battery 700Ah & 820Ah) .......................................... 1 43 .................... 815006 ..................................... Lever ....................................................................................................... 1 For Trucks with Battery Rollers 44 .................... 804207 ..................................... Roller ...................................................................................................... 6 45 .................... 804681 ..................................... Bearing Ball ............................................................................................. 12 46 .................... 804208 ..................................... Roller Axle .............................................................................................. 6 Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.6-2140

02 REV. 11/05

27A

SEAT AND PAN

1

3

19

7

20 2

21

8

PU SH

21

4 6

13

9

14 11 Chassis

18

12 4 17

10 5

4

17 16 16

15

15 Drive Frame

MP-2140-067 MP-1.7-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05

28M1.0-0000-00028

SEAT AND PAN INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 811915-001 .............................. Seat & Pan (black cloth/without Drive in Racking) .................................. 1 811915-003 .............................. Seat & Pan (PVC/without Drive in Racking) ........................................... 1 811915-005 .............................. Seat & Pan (48V Heated Cushion & Backrest/without Drive in Racking) 1 1 .............................................................................. Seat (see Section Seat) .................................................................... 1 2* .......................... 811917 ..................................... Seat Pan ............................................................................................ 1 3 ........................... 050005-022 .............................. Screw ................................................................................................ 3 4 ........................... 050008-024 .............................. Nut ..................................................................................................... 4 5* .......................... 791469-001 .............................. Seat Moulding .................................................................................... 1 6* .......................... 050006-035 .............................. Screw ................................................................................................ 7 7 ........................... 791466 ..................................... Handle Pocket ................................................................................... 1 8 ........................... 791635 ..................................... Vice Action Latch .............................................................................. 1 9 ........................... 808945 ..................................... Stay ................................................................................................... 1 10 .......................... 815247 ..................................... Bracket .............................................................................................. 1 11 .......................... 808947 ..................................... Bracket .............................................................................................. 1 12 .......................... 808949 ..................................... Pin ..................................................................................................... 1 13 .......................... 050073-004 .............................. Washer .............................................................................................. 1 14 .......................... 050070-001 .............................. Screw ................................................................................................ 1 15 .......................... 812345 ..................................... Plate .................................................................................................. 2 16 .......................... 811925 ..................................... Bracket .............................................................................................. 2 17 .......................... 050006-053 .............................. Screw ................................................................................................ 4 18 .......................... 051068-002 .............................. Spring ................................................................................................ 1 19 .......................... 050005-024 .............................. Screw ................................................................................................ 1 20 .......................... 816474 ..................................... Stop ................................................................................................... 1 21 .......................... 050009-018 .............................. Washer .............................................................................................. 2

* ........................... 811916 ..................................... Pan Mounting (included 2, 5, 6) ......................................................... 1

Not illustrated 795289 ..................................... Cable Seat ......................................................................................... 1 796216 ..................................... Seat Stop (Drive in Racking) .................................................................. 2 050005-024 .............................. Screw (Drive in Racking) ........................................................................ 4

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.7-2140

01 REV. 05/05

29

SEAT 27

26

27

28 5

27

2

25

25

3 25

1 5

4

8 7 6

10

5

11

7 9 12 9 9

12

9

13 15

9

14

15 17

16

15

16 23

21

24 22

16 19 29

5

7

7 19 19 20

18 24

MP-2140-068 MP-1.7-2140

30M1.0-0000-00030

MP-ESR4500-GB 06/04 • Printed in Germany

SEAT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 807433-001 .............................. Seat (black cloth) ................................................................................... 1 807433-003 .............................. Seat (PVC) ............................................................................................. 1 796781 ..................................... Seat (PVC/ Heated) ................................................................................ 1 1 ........................... 791653-001 .............................. Pad (only for 807433-001) ................................................................. 1 808493 ..................................... Pad (only for 807433-003) ................................................................. 1 808494 ..................................... Pad (only for 796781) ........................................................................ 1 2 ........................... 791653-002 .............................. Pad (only for 807433-001) ................................................................. 1 808495 ..................................... Pad (only for 807433-003) ................................................................. 1 808496 ..................................... Pad (only for 796781) ........................................................................ 1 3 ........................... 791691-001 .............................. Seat Back ......................................................................................... 1 4 ........................... 791691-002 .............................. Seat Plate .......................................................................................... 1 5 ........................... 791691-003 .............................. Attachment ........................................................................................ 3 6 ........................... 791691-004 .............................. Frame Seat ........................................................................................ 1 7 ........................... 791691-005 .............................. Wear Strips ....................................................................................... 1 8 ........................... 791691-006 .............................. Cover ................................................................................................ 1 9 ........................... 791691-007 .............................. Cable Assembly ................................................................................ 1 10 .......................... 791691-008 .............................. Latch Adjustment .............................................................................. 1 11 .......................... 791691-009 .............................. Cover Suspension ............................................................................. 1 12 .......................... 791691-010 .............................. Repair Kit .......................................................................................... 1 13 .......................... 791691-011 .............................. Weight Adjustment ............................................................................ 1 14 .......................... 791691-012 .............................. Latch (inclusive 13) ........................................................................... 1 15 .......................... 808497 ..................................... Slide Non Locking ............................................................................. 1 16 .......................... 808498 ..................................... Slide Locking (inclusive 29) ............................................................... 1 17 .......................... 791691-015 .............................. Support inner ..................................................................................... 1 18 .......................... 791691-016 .............................. Support outer .................................................................................... 1 19 .......................... 791691-017 .............................. Buffer Kit ........................................................................................... 1 20 .......................... 791691-018 .............................. Latch ................................................................................................. 1 21 .......................... 791691-019 .............................. Bracket Weight Adjustment ............................................................... 1 22 .......................... 808499 ..................................... Spring ................................................................................................ 1 23 .......................... 791691-021 .............................. Latch ................................................................................................. 1 24 .......................... 791691-022 .............................. Dashpot Assembly ............................................................................ 1 25 .......................... 791691-023 .............................. Bracket .............................................................................................. 1 26 .......................... 808500 ..................................... Spring ................................................................................................ 2 27 .......................... 808501 ..................................... Seat Switch Assembly (inclusive 26) ................................................ 1 28 .......................... 808502 ..................................... Cover Assembly ............................................................................... 1 29 .......................... 807434 ..................................... Cover Rail ......................................................................................... 1

Not illustrated 808503 ..................................... Harness Assembly (only for Heated Seat) ........................................ 1 808123-003 ............................... Pin Housing ................................................................................. 1 792882 ...................................... Pin Crimp ..................................................................................... 4 793091-003 ............................... Anti Back Out .............................................................................. 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.7-2140

31

SEAT 27

26

27

28 5

27

2

25

25

3 25

1 5

4

8 7 6

10

5

11

7 9 12 9 9

12

9

13 15

9

14

15 17

16

15

16 23

21

24 22

16 19 29

5

7

7 19 19 20

18 24

MP-2140-068 MP-1.7-2140

M1.0-0000-00030 30A

MP-ESR4500-GB 06/04 • Printed in Germany

SEAT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 815872-001 .............................. Seat (black cloth) ................................................................................... 1 815872-003 .............................. Seat (PVC) ............................................................................................. 1 796781 ..................................... Seat (PVC/ Heated) ................................................................................ 1 1 ........................... 816634 ..................................... Pad (only for 815872-001) ................................................................. 1 816635 ..................................... Pad (only for 815872-003) ................................................................. 1 808494 ..................................... Pad (only for 796781) ........................................................................ 1 2 ........................... 791653-002 .............................. Pad (only for 815872-001) ................................................................. 1 808495 ..................................... Pad (only for 815872-003) ................................................................. 1 808496 ..................................... Pad (only for 796781) ........................................................................ 1 3 ........................... 791691-001 .............................. Seat Back ......................................................................................... 1 4 ........................... 791691-002 .............................. Seat Plate .......................................................................................... 1 5 ........................... 791691-003 .............................. Attachment ........................................................................................ 3 6 ........................... 791691-004 .............................. Frame Seat ........................................................................................ 1 7 ........................... 791691-005 .............................. Wear Strips ....................................................................................... 1 8 ........................... 791691-006 .............................. Cover ................................................................................................ 1 9 ........................... 791691-007 .............................. Cable Assembly ................................................................................ 1 10 .......................... 791691-008 .............................. Latch Adjustment .............................................................................. 1 11 .......................... 791691-009 .............................. Cover Suspension ............................................................................. 1 12 .......................... 791691-010 .............................. Repair Kit .......................................................................................... 1 13 .......................... 791691-011 .............................. Weight Adjustment ............................................................................ 1 14 .......................... 791691-012 .............................. Latch (inclusive 13) ........................................................................... 1 15 .......................... 808497 ..................................... Slide Non Locking ............................................................................. 1 16 .......................... 808498 ..................................... Slide Locking (inclusive 29) ............................................................... 1 17 .......................... 791691-015 .............................. Support inner ..................................................................................... 1 18 .......................... 791691-016 .............................. Support outer .................................................................................... 1 19 .......................... 791691-017 .............................. Buffer Kit ........................................................................................... 1 20 .......................... 791691-018 .............................. Latch ................................................................................................. 1 21 .......................... 791691-019 .............................. Bracket Weight Adjustment ............................................................... 1 22 .......................... 808499 ..................................... Spring ................................................................................................ 1 23 .......................... 791691-021 .............................. Latch ................................................................................................. 1 24 .......................... 791691-022 .............................. Dashpot Assembly ............................................................................ 1 25 .......................... 791691-023 .............................. Bracket .............................................................................................. 1 26 .......................... 808500 ..................................... Spring ................................................................................................ 2 27 .......................... 808501 ..................................... Seat Switch Assembly (inclusive 26) ................................................ 1 28 .......................... 808502 ..................................... Cover Assembly ............................................................................... 1 29 .......................... 807434 ..................................... Cover Rail ......................................................................................... 1

Not illustrated 808503 ..................................... Harness Assembly (only for Heated Seat) ........................................ 1 808123-003 ............................... Pin Housing ................................................................................. 1 792882 ...................................... Pin Crimp ..................................................................................... 4 793091-003 ............................... Anti Back Out .............................................................................. 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.7-2140

01 REV. 05/05

31A

REAR MIRROR 1

2

5

3

4

6 7

MP-2140-066 MP-1.9-2140

32M1.0-0000-00032

MP-ESR4500-GB 06/04 • Printed in Germany

REAR MIRROR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 796090 ..................................... Rear Mirror .............................................................................................. 1 1 ........................... 050005-062 .............................. Screw ................................................................................................ 2 053050-006 .............................. Adhesive ........................................................................................... AR 2 ........................... 795977 ..................................... Clamp ................................................................................................ 1 3* .......................... 795438 ..................................... Bracket .............................................................................................. 1 4* .......................... 795442 ..................................... Adjuster ............................................................................................. 1 5* .......................... 050005-022 .............................. Screw ................................................................................................ 1 6* .......................... 050008-026 .............................. Nut ..................................................................................................... 1 7* .......................... 793779 ..................................... Mirror ................................................................................................. 1

* ........................... 795437 ..................................... Mirror Assembly (included 3 - 7) ....................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.9-2140

33

GUIDE WHEELS

A

8

1

2 3 4

5

6

4

7 MP-2140-074 MP-1.9-2140

34M1.0-0000-00034

MP-ESR4500-GB 06/04 • Printed in Germany

GUIDE WHEELS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 796057-*** ............................... Guide Wheels .......................................................................................... 4 1 ........................... 796050-001 .............................. Shim (1,0 mm) ................................................................................... AR 796050-002 .............................. Shim (3,0 mm) ................................................................................... AR 2 ........................... 796046-*** ................................ Bracket .............................................................................................. 4 3 ........................... 050067-044 .............................. Screw ................................................................................................ 16 4* .......................... 050012-067 .............................. Circlip ................................................................................................ 8 5* .......................... 055002-025 .............................. Bearing Ball ....................................................................................... 4 6* .......................... 796146 ..................................... Rim .................................................................................................... 4 796147 ..................................... Wheel ................................................................................................ 4 7 ........................... 050012-056 .............................. Circlip ................................................................................................ 4 8 ........................... 796051-*** ................................ Bracket .............................................................................................. 4

* ........................... 796049 ..................................... Wheel Assembly (included 4 - 6) ...................................................... 4

A

Position 0

Position 2

Position 8

25 mm

796057-001

796046-001

30 mm

796057-002

796046-002

35 mm

796057-003

796046-003

40 mm

796057-004

796046-004

45 mm

796057-005

796046-005

50 mm

796057-006

796046-006

55 mm

796057-007

796046-007

60 mm

796057-008

796051-001

65 mm

796057-009

796051-002

70 mm

796057-010

796051-003

75 mm

796057-011

796051-004

80 mm

796057-012

796051-005

85 mm

796057-013

796051-006

90 mm

796057-014

796051-007 Tab017

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.9-2140

35

OVERHEAD GUARD 14 7

11 12

14 8 14

14

13 12 6 5 6 5 6 9 13

10

5 6

4

2

3 2 1 3

Chassis

MP-2140-082 MP-1.9-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05

36M1.0-0000-00036

OVERHEAD GUARD INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 796328 ..................................... Overhead Guard ..................................................................................... 1 2 ..................... 050067-053 .............................. Screw ...................................................................................................... 2 3 ..................... 050068-006 .............................. Nut .......................................................................................................... 2 4 ..................... 815110 ..................................... Overhead Guard ..................................................................................... 1 5 ..................... 795977 ..................................... Clamp ...................................................................................................... 12 6 ..................... 050005-085 .............................. Screw ...................................................................................................... 24 050008-018 .............................. Nut .......................................................................................................... 24 7 ..................... 815111 ..................................... Cover ...................................................................................................... 1 8 ..................... 815155 ..................................... Bracket ................................................................................................... 1 9 ..................... 815154 ..................................... Bracket ................................................................................................... 1 10 .................... 815157 ..................................... Bracket ................................................................................................... 1 11 .................... 815156 ..................................... Bracket ................................................................................................... 1 12 .................... 050071-037 .............................. Screw ...................................................................................................... 2 13 .................... 050008-025 .............................. Nut .......................................................................................................... 2 14 .................... 050071-021 .............................. Screw ...................................................................................................... 13

815109 ..................................... Overhead Guard Assembly (included 4 - 6) ........................................... 1 815153 ..................................... Cover Assembly (included 5 - 14) .......................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.9-2140

01 REV. 05/05

37

ACCESSORIES 32 2 1 8 31 11

8

7 6

29

1 9 30

3 5

4 10

28 8 11 1 1

12

8 13 15

11 27

24

8

1

25

11 20 16

21

16 17

26 18 17 14

15

22 19

8

1

14

16

20 17

21

11 18

17 16 15 24

22 25

23 26

MP-2140-085 MP-1.9-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05

38M1.0-0000-00038

ACCESSORIES INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 050005-016 .............................. Screw ...................................................................................................... AR 2 ..................... 795977 ..................................... Clamp ...................................................................................................... 3 3 ..................... 814650 ..................................... Bracket ................................................................................................... 1 4 ..................... 050008-018 .............................. Nut .......................................................................................................... 6 5 ..................... 050067-007 .............................. Screw ...................................................................................................... 4 6 ..................... 814657 ..................................... Shim ........................................................................................................ 2 7 ..................... 128362 ..................................... Clamp ...................................................................................................... 1 8 ..................... 127697 ..................................... Clamp ...................................................................................................... AR 9 ..................... 124530 ..................................... Plug ......................................................................................................... 1 10 .................... 130814-001 .............................. Tube ........................................................................................................ 1 11 .................... 128362 ..................................... Clamp ...................................................................................................... AR 12 .................... 814715 ..................................... Bracket ................................................................................................... 1 13 .................... 050003-018 .............................. Screw ...................................................................................................... 4 14 .................... 130048 ..................................... Bracket ................................................................................................... AR 15 .................... 050067-014 .............................. Screw ...................................................................................................... AR 16 .................... 130064 ..................................... Bushing ................................................................................................... AR 17 .................... 050009-025 .............................. Washer ................................................................................................... AR 18 .................... 050008-034 .............................. Nut .......................................................................................................... AR 19 .................... 814664 ..................................... Pad .......................................................................................................... 1 20 .................... 050006-022 .............................. Screw ...................................................................................................... AR 21 .................... 814566 ..................................... Housing ................................................................................................... AR 22 .................... 814594 ..................................... Spring ..................................................................................................... AR 23 .................... 130008 ..................................... Pad .......................................................................................................... 1 24 .................... 130060 ..................................... Bracket ................................................................................................... AR 25 .................... 050006-024 .............................. Screw ...................................................................................................... AR 26 .................... 130071 ..................................... Holder ..................................................................................................... AR 27 .................... 130050 ..................................... Plate ........................................................................................................ 1 28 .................... 125502 ..................................... Storage Pocket ....................................................................................... 1 29 .................... 125503 ..................................... Mount ...................................................................................................... 1 30 .................... 050005-024 .............................. Screw ...................................................................................................... 1 31 .................... 050008-025 .............................. Nut .......................................................................................................... 1 32 .................... 050005-085 .............................. Screw ...................................................................................................... 6

814652 ..................................... Bracket Assembly (included 1, 3, 5 -10) ................................................. 1 814858 ..................................... Clamp Assembly (included 1, 8, 11) ....................................................... 1 814720 ..................................... Mounting Plate Assembly (included 1, 8, 11 -13) .................................... 1 814716 ..................................... Pad Assembly (included 1, 8, 11, 14 - 22) .............................................. 1 814856 ..................................... Clip and Hook Assembly (included 1, 8, 11, 14- 18, 20 - 26) .................. 1 814722 ..................................... Hook Assembly (included 1, 8, 11, 15, 24 - 27) ...................................... 1 814857 ..................................... Storage Pocket Assembly (included 1, 8, 11, 28 - 31) ............................ 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-1.9-2140

02 REV. 11/05

39

Page intentionally left blank

Printed in Germany

40M1.0-0000-00040

SECTION 2

Printed in Germany

41

TUBE/HOSE LAYOUT 16 15 I

22

23

H

20 23

19

17 12

11

23

13

19 21

D

13

22

18

J

14 F

14

13

B

28 I

14 14

G

H

F E

D

J

C G

2

3

5

C

B A

3 1

7

24

K

31 4

24

30 29

25

25 E

A

27

5

26

8

3

K

9 10 MP-2140-070 MP-2.1-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05

42M1.0-0000-00042

TUBE/HOSE LAYOUT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 050017-022 .............................. Screw ...................................................................................................... 3 050068-003 .............................. Nut .......................................................................................................... 3 2 ..................... 815253 ..................................... Hose Clamp (only for 1285mm width) ..................................................... 1 816898 ..................................... Washer (only for 1285mm width) ........................................................... 1 3 ..................... 050005-076 .............................. Screw ...................................................................................................... AR 4 ..................... 813158 ..................................... Plate (only for 1285mm width) ................................................................. 1 5 ..................... 812048-001 .............................. Hose clamp ............................................................................................. 4 6 ..................... 050005-066 .............................. Screw ...................................................................................................... 2 7 ..................... 050068-003 .............................. Nut .......................................................................................................... 4 8 ..................... 813159 ..................................... Cover ...................................................................................................... 1 9 ..................... 050067-024 .............................. Screw ...................................................................................................... 2 10 .................... 050078-009 .............................. Blind Rivet Nut ........................................................................................ 2 11 .................... 813145 ..................................... Hose ....................................................................................................... 1 12 .................... 813146 ..................................... Hose ....................................................................................................... 1 13 .................... 813149 ..................................... Hollow Bolt .............................................................................................. 4 14 .................... 813150 ..................................... Seal Ring ................................................................................................ 4 15 .................... 807075 ..................................... Bracket (see Section 2.8) ....................................................................... 1 16 .................... 054176-001 .............................. Adaptor ................................................................................................... 2 17 .................... 812979 ..................................... Hose ....................................................................................................... 1 18 .................... 812980 ..................................... Hose ....................................................................................................... 1 19 .................... 054156-002 .............................. Adaptor ................................................................................................... 2 20 .................... 812039 ..................................... Counter Balance Valve ............................................................................ 1 21 .................... 812040 ..................................... Counter Balance Valve ............................................................................ 1 22 .................... 054171-002 .............................. Adaptor ................................................................................................... 2 23 .................... 812033 ..................................... Hose Assembly ....................................................................................... 1 24 .................... 813147 ..................................... Hollow Bolt .............................................................................................. 2 25 .................... 813148 ..................................... Seal Ring ................................................................................................ 2 26 .................... 812977 ..................................... Hose ....................................................................................................... 1 27 .................... 812978 ..................................... Hose ....................................................................................................... 1 28 .................... 054191-006 .............................. Hose Clamp ............................................................................................ 1 29 .................... 812048-002 .............................. Hose clamp ............................................................................................. 2 30 .................... 050005-025 .............................. Screw ...................................................................................................... 2 31 .................... 050008-024 .............................. Nut .......................................................................................................... 2

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-2.1-2140

02 REV. 11/05

43

HYDRAULIC TANK 4

17

16

9 15

2

2 3

10 5

4

6

14

8

13

11 7 12 1

19

18

MP-2140-036 MP-2.3-2140

44M1.0-0000-00044

MP-ESR4500-GB 06/04 • Printed in Germany

HYDRAULIC TANK INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 812312-001 .............................. Hydraulic Tank Assembly ....................................................................... 1 1* .......................... 806776 ..................................... Tank ................................................................................................... 1 805299 ..................................... Screw Plug ........................................................................................ 1 2* .......................... 804859-002 .............................. Rubber .............................................................................................. 2 3 ........................... 813252 ..................................... Clamp ................................................................................................ 1 4 ........................... 050008-021 .............................. Nut ..................................................................................................... 4 5 ........................... 807978 ..................................... Clamp ................................................................................................ 1 6 ........................... 050008-030 .............................. Nut ..................................................................................................... 2 7 ........................... 812210 ..................................... Clamp ................................................................................................ 1 8 ........................... 050006-032 .............................. Screw ................................................................................................ 2 9* .......................... 806835 ..................................... Gasket .............................................................................................. 1 10* ......................... 806842 ..................................... Suction Line ....................................................................................... 1 11* ......................... 793539 ..................................... Seal Bonded ...................................................................................... 1 12* ......................... 793192 ..................................... Suction Filter ..................................................................................... 1 13* ......................... 813251 ..................................... Heat Shield ........................................................................................ 1 14* ......................... 050006-026 .............................. Screw ................................................................................................ 7 15* ......................... 808413 ..................................... Filter Assembly ................................................................................. 1 808504 ...................................... Filter Element ............................................................................... 1 808505 ...................................... Cap Breather ............................................................................... 1 16* ......................... 051071-001 .............................. Adaptor .............................................................................................. 1 053050-021 .............................. Teflon-Tape ........................................................................................ AR 17* ......................... 791415-020 .............................. Washer .............................................................................................. 2 18 .......................... 808360 ..................................... Mat .................................................................................................... 1 19 .......................... 055053-003 .............................. Pin ..................................................................................................... 2

* ........................... 812313 ..................................... Tank Assembly (included 1, 2, 9-17) ................................................. 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-2.3-2140

01 REV. 05/05

45

HYDRAULIC TT MAST 34 20 30 20

4

18 26

17

19

Fork Carriage

26

26

16 32

29 33

13 27

2

35

28 26

26 23

31

21 15

3

22

26

9

2 26

25

14 36

8 24

10

10

12

11

Chassi

13

9

14

Index 14 only to serial number cut 5A203818, see section 8.1

7 12

6

1 MP-2140-058

MP-2.8-2140

46M1.0-0000-00046

MP-ESR4500-GB 06/04 • Printed in Germany

HYDRAULIC TT MAST INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ........................................................................ Outermast (see Section 7.5) 2 ........................................................................ Lift Cylinder (see Section 8.1) 3 ........................................................................ 1 st Stage Mast (see Section 7.5) 4 ........................................................................ Free Lift Cylinder (see Section 8.2) 5 ..................... 807070 ..................................... Manifold Block ........................................................................................ 1 6 ..................... 050070-003 .............................. Screw ...................................................................................................... 2 7 ..................... 050073-005 .............................. Washer ................................................................................................... 2 8 ..................... 050008-038 .............................. Nut .......................................................................................................... 2 9 ..................... 064004-015 .............................. Adaptor ................................................................................................... 2 10 .................... 064004-001 .............................. Adaptor ................................................................................................... 2 11 .................... 807326 ..................................... Pipe ......................................................................................................... 1 12 .................... 064061-003 .............................. Elbow ...................................................................................................... 2 13 .................... 806992 ..................................... Hose Burst Valve .................................................................................... 2 14 .................... 064091-001 .............................. Plug ......................................................................................................... 2 15 .................... 806157 ..................................... Pipe ......................................................................................................... 1 050006-024 .............................. Screw ...................................................................................................... 2 050008-015 .............................. Nut .......................................................................................................... 2 16 .................... 807062-001-** .......................... Hose (see next Page) ............................................................................. 1 17 .................... 807320 ..................................... Bracket ................................................................................................... 1 18 .................... 050006-040 .............................. Screw ...................................................................................................... 1 19 .................... 050068-003 .............................. Nut .......................................................................................................... 1 20 ....................................................................... Pulley Hose (see Section 7.6) 21 .................... 806158 ..................................... Pipe ......................................................................................................... 1 22 .................... 050006-036 .............................. Screw ...................................................................................................... 2 23 .................... 050008-024 .............................. Nut .......................................................................................................... 2 24 .................... 064061-016 .............................. Elbow ...................................................................................................... 1 25 .................... 807075 ..................................... Bracket (see Section 2.1) ....................................................................... 1 050006-024 .............................. Screw ...................................................................................................... 2 050008-015 .............................. Nut .......................................................................................................... 2 26 .................... 054176-001 .............................. Adaptor ................................................................................................... 8 27 .................... 807072-*** ............................... Pipe (see next Page) ............................................................................... 1 28 .................... 807074-*** ............................... Pipe (see next Page) ............................................................................... 1 29 .................... 807076-001 .............................. Bracket ................................................................................................... 1 050006-040 .............................. Screw ...................................................................................................... 1 050068-003 .............................. Nut .......................................................................................................... 1 30 .................... 807062-002-** .......................... Hose ....................................................................................................... 2 31 .................... 807078 ..................................... Bracket ................................................................................................... 1 050006-036 .............................. Screw ...................................................................................................... 2 050008-024 .............................. Nut .......................................................................................................... 2 32 .................... 806160-*** ............................... Pipe (see next Page) ............................................................................... 1 33 .................... 806161-*** ............................... Pipe (see next Page) ............................................................................... 1 34 .................... 807062-003-** .......................... Hose (see next Page) ............................................................................. 2 35 .................... 810534 ..................................... Plate ........................................................................................................ 1 36 .................... 813277 ..................................... Pipe with Pressure Switch Assembly ..................................................... 1 813278 ..................................... Switch ............................................................................................... 1

Not illustrated 808996 ..................................... Clamp ...................................................................................................... AR 051051-009 .............................. Cable Tie ................................................................................................. AR

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-2.8-2140

47

HYDRAULIC TT MAST 34 20 30 20

4

18 26

17

19

Fork Carriage

26

26

16 32

29 33

14 27

2

35

28 26

26 23

31

21 15

3

22

26

9

2

8 13

26

25

36

24

10

10

12

11

Chassi

13

9 7 12

6

1 MP-2140-100 MP-2.8-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05 M1.0-0000-00046 46A

HYDRAULIC TT MAST INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ........................................................................ Outermast (see Section 7.5) 2 ........................................................................ Lift Cylinder (see Section 8.1) 3 ........................................................................ 1 st Stage Mast (see Section 7.5) 4 ........................................................................ Free Lift Cylinder (see Section 8.2) 5 ..................... 807070 ..................................... Manifold Block ........................................................................................ 1 6 ..................... 050070-003 .............................. Screw ...................................................................................................... 2 7 ..................... 050073-005 .............................. Washer ................................................................................................... 2 8 ..................... 050008-038 .............................. Nut .......................................................................................................... 2 9 ..................... 064004-015 .............................. Adaptor ................................................................................................... 2 10 .................... 064004-001 .............................. Adaptor ................................................................................................... 2 11 .................... 807326 ..................................... Pipe ......................................................................................................... 1 12 .................... 064061-003 .............................. Elbow ...................................................................................................... 2 13 .................... 806992 ..................................... Hose Burst Valve .................................................................................... 2 14 ....................................................................... Hose Burst Valve (see Section 8.2) ........................................................ 1 15 .................... 806157 ..................................... Pipe ......................................................................................................... 1 050006-024 .............................. Screw ...................................................................................................... 2 050008-015 .............................. Nut .......................................................................................................... 2 16 .................... 807062-001-** .......................... Hose (see next Page) ............................................................................. 1 17 .................... 807320 ..................................... Bracket ................................................................................................... 1 18 .................... 050006-040 .............................. Screw ...................................................................................................... 1 19 .................... 050068-003 .............................. Nut .......................................................................................................... 1 20 ....................................................................... Pulley Hose (see Section 7.6) 21 .................... 806158 ..................................... Pipe ......................................................................................................... 1 22 .................... 050006-036 .............................. Screw ...................................................................................................... 2 23 .................... 050008-024 .............................. Nut .......................................................................................................... 2 24 .................... 064061-016 .............................. Elbow ...................................................................................................... 1 25 .................... 807075 ..................................... Bracket (see Section 2.1) ....................................................................... 1 050006-024 .............................. Screw ...................................................................................................... 2 050008-015 .............................. Nut .......................................................................................................... 2 26 .................... 054176-001 .............................. Adaptor ................................................................................................... 8 27 .................... 807072-*** ............................... Pipe (see next Page) ............................................................................... 1 28 .................... 807074-*** ............................... Pipe (see next Page) ............................................................................... 1 29 .................... 807076-001 .............................. Bracket ................................................................................................... 1 050006-040 .............................. Screw ...................................................................................................... 1 050068-003 .............................. Nut .......................................................................................................... 1 30 .................... 807062-002-** .......................... Hose ....................................................................................................... 2 31 .................... 807078 ..................................... Bracket ................................................................................................... 1 050006-036 .............................. Screw ...................................................................................................... 2 050008-024 .............................. Nut .......................................................................................................... 2 32 .................... 806160-*** ............................... Pipe (see next Page) ............................................................................... 1 33 .................... 806161-*** ............................... Pipe (see next Page) ............................................................................... 1 34 .................... 807062-003-** .......................... Hose (see next Page) ............................................................................. 2 35 .................... 810534 ..................................... Plate ........................................................................................................ 1 36 .................... 813277 ..................................... Pipe with Pressure Switch Assembly ..................................................... 1 813278 ..................................... Pipe ................................................................................................... 1 810059 ..................................... Switch ............................................................................................... 1 050011-017 .............................. Washer .............................................................................................. 1

Not illustrated 808996 ..................................... Clamp ...................................................................................................... AR 051051-009 .............................. Cable Tie ................................................................................................. AR

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-2.8-2140

01 REV. 05/05

47A

HYDRAULIC TT MAST 1.4t/1.6t Position 16

Position 30

Position 34

Collapsed Height

807062-001-01

807062-002-01

807062-003-01

2022mm

807062-001-02

807062-002-02

807062-003-02

2172mm

807062-001-03

807062-002-03

807062-003-03

2322mm

807062-001-04

807062-002-04

807062-003-04

2472mm

807062-001-05

807062-002-05

807062-003-05

2572mm

807062-001-06

807062-002-06

807062-003-06

2772mm

807062-001-07

807062-002-07

807062-003-07

2922mm

807062-001-08

807062-002-08

807062-003-08

3042mm

807062-001-09

807062-002-09

807062-003-09

3192mm

807062-001-10

807062-002-10

807062-003-10

3347mm

807062-001-11

807062-002-11

807062-003-11

3492mm

807062-001-12

807062-002-12

807062-003-12

3692mm

807062-001-13

807062-002-13

807062-003-13

3842mm

807062-001-14

807062-002-14

807062-003-14

3952mm Tab013gb

Position 27

Position 28

Position 32

Position 33

Collapsed Height

807072-001

807074-001

806160-001

806161-001

2022mm

807072-002

807074-002

806160-002

806161-002

2172mm

807072-003

807074-003

806160-003

806161-003

2322mm

807072-004

807074-004

806160-004

806161-004

2472mm

807072-005

807074-005

806160-005

806161-005

2572mm

807072-006

807074-006

806160-006

806161-006

2772mm

807072-007

807074-007

806160-007

806161-007

2922mm

807072-008

807074-008

806160-008

806161-008

3042mm

807072-009

807074-009

806160-009

806161-009

3192mm

807072-010

807074-010

806160-010

806161-010

3347mm

807072-011

807074-011

806160-011

806161-011

3492mm

807072-012

807074-012

806160-012

806161-012

3692mm

807072-013

807074-013

806160-013

806161-013

3842mm

807072-014

807074-014

806160-014

806161-014

3952mm Tab014gb

MP-2.8-2140

48M1.0-0000-00048

MP-ESR4500-GB 06/04 • Printed in Germany

HYDRAULIC TT MAST 2.0t Position 16

Position 30

Position 34

Collapsed Height

807062-001-01

807062-002-01

807062-003-01

2022mm

807062-001-02

807062-002-02

807062-003-02

2172mm

807062-001-04

807062-002-04

807062-003-04

2472mm

807062-001-06

807062-002-06

807062-003-06

2772mm

807062-001-07

807062-002-07

807062-003-07

2922mm

807062-001-08

807062-002-08

807062-003-08

3042mm

807062-001-10

807062-002-10

807062-003-10

3347mm

807062-001-12

807062-002-12

807062-003-12

3692mm

807062-001-13

807062-002-13

807062-003-13

3842mm

807062-001-14

807062-002-14

807062-003-14

3952mm

807062-001-15

807062-002-15

807062-003-15

4252mm

807062-001-16

807062-002-16

807062-003-16

4452mm Tab015gb

Position 27

Position 28

Position 32

Position 33

Collapsed Height

807072-001

807074-001

806160-001

806161-001

2022mm

807072-002

807074-002

806160-002

806161-002

2172mm

807072-004

807074-004

806160-004

806161-004

2472mm

807072-006

807074-006

806160-006

806161-006

2772mm

807072-007

807074-007

806160-007

806161-007

2922mm

807072-008

807074-008

806160-008

806161-008

3042mm

807072-010

807074-010

806160-010

806161-010

3347mm

807072-012

807074-012

806160-012

806161-012

3692mm

807072-013

807074-013

806160-013

806161-013

3842mm

807072-014

807074-014

806160-014

806161-014

3952mm

807072-015

807074-015

806160-015

806161-015

4252mm

807072-016

807074-016

806160-016

806161-016

4452mm Tab016gb

MP-ESR4500-GB 06/04 • Printed in Germany

MP-2.8-2140

49

VALVE BLOCK

4 3

1

A T P

A1 B1

B2

1

A2

2

1

1

MP-2140-069 MP-2.10-2140

50M1.0-0000-00050

MP-ESR4500-GB 06/04 • Printed in Germany

VALVE BLOCK INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 812050 ..................................... Valve Block ............................................................................................. 1 1 ........................... 812041 ..................................... Solenoid ............................................................................................ 4 2 ........................... 812043 ..................................... Lift/Lower Valve ................................................................................. 1 3 ........................... 812051 ..................................... Pressure Relieve Valve ..................................................................... 1 4 ........................... 812044 ..................................... Filter .................................................................................................. 1

812052 ..................................... Seal Kit .............................................................................................. 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-2.10-2140

51

PUMP

MP-2140-080 MP-2.12-2140

52M1.0-0000-00052

MP-ESR4500-GB 06/04 • Printed in Germany

PUMP INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 790940-002 .............................. Pump (Assembly - see next Page) ......................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-2.12-2140

53

PUMP MOTOR AND PUMP 5

4 3

2

16 17

3

18 1 19 26 6 20

13

21 23 24

7

22 8

15 25

14

10 11

Drive Plate

9

13 12

MP-2140-079 MP-2.13-2140

54M1.0-0000-00054

MP-ESR4500-GB 06/04 • Printed in Germany

PUMP MOTOR AND PUMP INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 813734 ..................................... Pump Motor and Pump Assembly (without 26) ....................................... 1 1 ........................... 811896 ..................................... Bracket .............................................................................................. 1 2 .............................................................................. Pump Motor (see next Page) ............................................................. 1 3 ........................... 812174 ..................................... Puffer ................................................................................................ 6 4 ........................... 050009-031 .............................. Washer .............................................................................................. 3 5 ........................... 050007-045 .............................. Screw ................................................................................................ 3 6 ........................... 812889 ..................................... Puffer -Tube ....................................................................................... 3 7 ........................... 791534 ..................................... Washer Sealing ................................................................................. 1 8 .............................................................................. Pump (see Section 2.12) ................................................................... 1 9 ........................... 050067-034 .............................. Screw ................................................................................................ 2 10 .......................... 054002-035 .............................. O-Ring ............................................................................................... 1 11 .......................... 790491 ..................................... Inlet Pump ......................................................................................... 1 12 .......................... 050005-060 .............................. Screw ................................................................................................ 4 13 .......................... 054191-001 .............................. Clamp ................................................................................................ AR 054191-004 .............................. Clamp ................................................................................................ AR 14 .......................... 812204 ..................................... Hose .................................................................................................. 1 15 .......................... 054002-034 .............................. O-Ring ............................................................................................... 1 16 .......................... 812205 ..................................... Tube ................................................................................................... 1 17 .......................... 050005-063 .............................. Screw ................................................................................................ 2 18 .......................... 050005-062 .............................. Screw ................................................................................................ 2 19* ......................... 812207 ..................................... Bracket .............................................................................................. 1 20* ......................... 050078-008 .............................. Blind Rivet Nut .................................................................................. 8 21* ......................... 050078-007 .............................. Blind Rivet Nut .................................................................................. 5 22 .......................... 793288 ..................................... Clip .................................................................................................... 5 23 .......................... 050003-013 .............................. Screw ................................................................................................ 5 24* ......................... 050078-001 .............................. Blind Rivet Nut .................................................................................. 2 25 .......................... 050067-022 .............................. Screw ................................................................................................ 2 26 .................... 050067-044 .............................. Screw ...................................................................................................... 2

* ........................... 813239 ..................................... Bracket Assembly (included 19 - 21 & 24) ........................................ 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-2.13-2140

01 REV. 05/05

55

PUMP MOTOR 1 1

1 7 2

8

8 8

3

3

3

3 4

8 6 9

8

5

10

4 1 1

MP-2140-087 MP-2.13-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05

56M1.0-0000-00056

PUMP MOTOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 811853 ..................................... Pump Motor Asssembly .......................................................................... 1 1 ........................... 816766 ..................................... Screw - Kit ......................................................................................... 1 2 ........................... 816767 ..................................... End Shield ......................................................................................... 1 3 ........................... 816768 ..................................... Pin - Kit .............................................................................................. 1 4 ........................... 816770 ..................................... Armature (included 5 & 6) ................................................................. 1 5 ................................. 816769 ...................................... Sensor Bearing ............................................................................ 1 6 ................................. 816772 ...................................... Bearing Ball ................................................................................. 1 7 ........................... 814836 ..................................... Stator ................................................................................................ 1 8 ........................... 816771 ..................................... Terminal Block - Kit ............................................................................ 1 9 .............................................................................. Power Cable (see Section 4.1) .......................................................... 3 10 .......................... 816773 ..................................... End Shield ......................................................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-2.13-2140

01 REV. 05/05

57

Page intentionally left blank

Printed in Germany

58M1.0-0000-00058

SECTION 3

Printed in Germany

59

DRIVE UNIT 4

3 2

22

21

20

20

19

19 5

23

23 15

8

13 24

14

1

7

9 25 16

17 18 12

26

6

11

10

MP-2140-077 MP-3.0-2140

60M1.0-0000-00060

MP-ESR4500-GB 06/04 • Printed in Germany

DRIVE UNIT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 811141 ..................................... Drive Plate .............................................................................................. 1 2 ........................................................................ Drive Motor (see Section 3.2) ................................................................. 1 3 ........................................................................ Drive Motor Brake (see Section 5.6) ....................................................... 1 4 ..................... 050005-097 .............................. Screw ...................................................................................................... 3 5 ..................... 050005-024 .............................. Screw ...................................................................................................... 6 6 ..................... 812238 ..................................... Gearbox (see Section 3.1) ...................................................................... 1 7 ..................... 050010-041 .............................. Washer ................................................................................................... 6 8 ..................... 050005-096 .............................. Screw ...................................................................................................... 6 9 ..................... 050007-043 .............................. Screw ...................................................................................................... 2 10 .................... 813816 ..................................... Drive Guard ............................................................................................ 1 11 .................... 807557 ..................................... Wheel ...................................................................................................... 1 810240 ..................................... Wheel (Freezer/Corrosion) ..................................................................... 1 12 .................... 050062-001 .............................. Nut .......................................................................................................... 7 13 ....................................................................... Steer Motor (see Section 6.2) ................................................................. 1 14 .................... 050006-039 .............................. Screw ...................................................................................................... 3 15 .................... 812169 ..................................... Spacer .................................................................................................... 3 16 .................... 812993 ..................................... Pinion ...................................................................................................... 1 17 .................... 813036 ..................................... Washer ................................................................................................... 1 18 .................... 050067-023 .............................. Screw ...................................................................................................... 1 19 .................... 813243 ..................................... Bracket ................................................................................................... 2 20 .................... 050006-033 .............................. Screw ...................................................................................................... 2 21 .................... 811378-002 .............................. Sensor Inductive Assembly .................................................................... 1 792881-002 .............................. Socket Housing ................................................................................. 1 792883 ..................................... Socket Crimp .................................................................................... 3 793091-002 .............................. Anti Backout ...................................................................................... 1 22 .................... 811378-001 .............................. Sensor Inductive Assembly .................................................................... 1 792881-003 .............................. Socket Housing ................................................................................. 1 792883 ..................................... Socket Crimp .................................................................................... 3 793091-002 .............................. Anti Backout ...................................................................................... 1 23 .................... 050008-061 .............................. Nut .......................................................................................................... 2 24 .................... 050067-052 .............................. Screw ...................................................................................................... 8 25 .................... 050006-040 .............................. Screw ...................................................................................................... 1 26 .................... 050008-024 .............................. Nut .......................................................................................................... 1

813038-002 .............................. Steer Sensor Assembly (included 19 - 21, 23) ....................................... 1 813038-001 .............................. Steer Sensor Assembly (included 19, 20, 22, 23) ................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-3.0-2140

61

DRIVE UNIT 4

3 2

22

21 13

20

20

19

19 14 5

23

23 15

8

24

27

1

7

28

9 29

25 16

17 18 30

12

26

6

11

10

MP-2140-111 MP-3.0-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05 M1.0-0000-00060 60A

DRIVE UNIT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 811141 ..................................... Drive Plate .............................................................................................. 1 2 ........................................................................ Drive Motor (see Section 3.2) ................................................................. 1 3 ........................................................................ Drive Motor Brake (see Section 5.6) ....................................................... 1 4 ..................... 050005-097 .............................. Screw ...................................................................................................... 3 5 ..................... 050005-024 .............................. Screw ...................................................................................................... 6 6 ..................... 812238 ..................................... Gearbox (see Section 3.1) ...................................................................... 1 7 ..................... 050010-041 .............................. Washer ................................................................................................... 6 8 ..................... 050005-096 .............................. Screw ...................................................................................................... 6 9 ..................... 050007-043 .............................. Screw ...................................................................................................... 2 10 .................... 813816 ..................................... Drive Guard ............................................................................................ 1 11 .................... 807557 ..................................... Wheel ...................................................................................................... 1 810240 ..................................... Wheel (Freezer/Corrosion) ..................................................................... 1 12 .................... 050062-001 .............................. Nut .......................................................................................................... 7 13 ....................................................................... Steer Motor (see Section 6.2) ................................................................. 1 14 .................... 050006-030 .............................. Screw ...................................................................................................... 3 15 .................... 816532 ..................................... Spacer .................................................................................................... 3 16 .................... 816533 ..................................... Pinion ...................................................................................................... 1 17 .................... 813036 ..................................... Washer ................................................................................................... 1 18 .................... 050067-023 .............................. Screw ...................................................................................................... 1 19 .................... 813243 ..................................... Bracket ................................................................................................... 2 20 .................... 050006-033 .............................. Screw ...................................................................................................... 2 21 .................... 811378-002 .............................. Sensor Inductive Assembly .................................................................... 1 792881-003 .............................. Socket Housing ................................................................................. 1 792883 ..................................... Socket Crimp .................................................................................... 3 793091-002 .............................. Anti Backout ...................................................................................... 1 22 .................... 811378-001 .............................. Sensor Inductive Assembly .................................................................... 1 792881-002 .............................. Socket Housing ................................................................................. 1 792883 ..................................... Socket Crimp .................................................................................... 3 793091-002 .............................. Anti Backout ...................................................................................... 1 23 .................... 050008-061 .............................. Nut .......................................................................................................... 2 24 .................... 050067-052 .............................. Screw ...................................................................................................... 8 25 .................... 050006-040 .............................. Screw ...................................................................................................... 1 26 .................... 050008-024 .............................. Nut .......................................................................................................... 1 27 .................... 050012-079 .............................. Circlip ...................................................................................................... 1 28 .................... 055017-004 .............................. Bearing ................................................................................................... 1 29 .................... 816534 ..................................... Adaptor ................................................................................................... 1 30 .................... 050005-106 .............................. Screw ...................................................................................................... 6

813038-002 .............................. Steer Sensor Assembly (included 19, 21, 23) ......................................... 1 813038-001 .............................. Steer Sensor Assembly (included 19, 22, 23) ......................................... 1 816531 ..................................... Adaptor Assembly (included 27 - 29) ...................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-3.0-2140

01 REV. 05/05

61A

DRIVE UNIT 4

3 2

22

21 13

20

20

19

19 14 5

23

23 15

8

24

27

1

7

28

9 29

25 16

17 18 30

12

26

6

11

10

MP-2140-111 MP-3.0-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05 M1.0-0000-00060 60B

DRIVE UNIT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 816262 ..................................... Drive Plate .............................................................................................. 1 2 ........................................................................ Drive Motor (see Section 3.2) ................................................................. 1 3 ........................................................................ Drive Motor Brake (see Section 5.6) ....................................................... 1 4 ..................... 050005-097 .............................. Screw ...................................................................................................... 3 5 ..................... 050005-024 .............................. Screw ...................................................................................................... 6 6 ..................... 812238 ..................................... Gearbox (see Section 3.1) ...................................................................... 1 7 ..................... 050010-041 .............................. Washer ................................................................................................... 6 8 ..................... 050005-096 .............................. Screw ...................................................................................................... 6 9 ..................... 050007-043 .............................. Screw ...................................................................................................... 2 10 .................... 813816 ..................................... Drive Guard ............................................................................................ 1 11 .................... 807557 ..................................... Wheel ...................................................................................................... 1 12 .................... 050062-001 .............................. Nut .......................................................................................................... 7 13 ....................................................................... Steer Motor (see Section 6.2) ................................................................. 1 14 .................... 050006-030 .............................. Screw ...................................................................................................... 3 15 .................... 816532 ..................................... Spacer .................................................................................................... 3 16 .................... 816404 ..................................... Pinion ...................................................................................................... 1 17 .................... 813036 ..................................... Washer ................................................................................................... 1 18 .................... 050067-023 .............................. Screw ...................................................................................................... 1 19 .................... 813243 ..................................... Bracket ................................................................................................... 2 20 .................... 050006-033 .............................. Screw ...................................................................................................... 2 21 .................... 811378-002 .............................. Sensor Inductive Assembly .................................................................... 1 792881-003 .............................. Socket Housing ................................................................................. 1 792883 ..................................... Socket Crimp .................................................................................... 3 793091-002 .............................. Anti Backout ...................................................................................... 1 22 .................... 811378-001 .............................. Sensor Inductive Assembly .................................................................... 1 792881-002 .............................. Socket Housing ................................................................................. 1 792883 ..................................... Socket Crimp .................................................................................... 3 793091-002 .............................. Anti Backout ...................................................................................... 1 23 .................... 050008-061 .............................. Nut .......................................................................................................... 2 24 .................... 050067-052 .............................. Screw ...................................................................................................... 8 25 .................... 050006-040 .............................. Screw ...................................................................................................... 1 26 .................... 050008-024 .............................. Nut .......................................................................................................... 1 27 .................... 050012-079 .............................. Circlip ...................................................................................................... 1 28 .................... 055017-004 .............................. Bearing ................................................................................................... 1 29 .................... 816534 ..................................... Adaptor ................................................................................................... 1 30 .................... 050005-106 .............................. Screw ...................................................................................................... 6

813038-002 .............................. Steer Sensor Assembly (included 19, 21, 23) ......................................... 1 813038-001 .............................. Steer Sensor Assembly (included 19, 22, 23) ......................................... 1 816531 ..................................... Adaptor Assembly (included 27 - 29) ...................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-3.0-2140

02 REV. 11/05

61B

GEAR BOX 1 2

3

4 7 2

6

5

8

15 12

9

16

13

10 11

14

17 37 18

13

24 23 25 44 38 36 18

42

27

2

30 35 29

26

27 28 34

19 43

22

30 41 20

40 39

31

21 33 32 22 MP-2140-089

MP-3.1-2140

62M1.0-0000-00062

MP-ESR4500-GB 06/04 • Printed in Germany

GEAR BOX INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 812238 ..................................... Gear Box ................................................................................................ 1 1 ........................... 808612 ..................................... Screw ................................................................................................ 15 2 ........................... 805164 ..................................... Washer .............................................................................................. 25 3 ........................... 808593 ..................................... Turntable ............................................................................................ 1 4 ........................... 808616 ..................................... Pin ..................................................................................................... 1 5 ........................... 808603 ..................................... O-Ring ............................................................................................... 1 6 ........................... 808601 ..................................... Seal ................................................................................................... 1 7 ........................... 050005-026 .............................. Screw ................................................................................................ 2 8 ........................... 808581 ..................................... Gear Rim ........................................................................................... 1 9 ........................... 808617 ..................................... Washer .............................................................................................. 1 10 .......................... 808615 ..................................... Washer .............................................................................................. 1 11 .......................... 808594 ..................................... Block ................................................................................................. 1 12 .......................... 808604 ..................................... O-Ring ............................................................................................... 1 13 .......................... 808599 ..................................... Bearing Ball ....................................................................................... 2 14 .......................... 808582 ..................................... Pinion ................................................................................................ 1 15 .......................... 808584 ..................................... Nut ..................................................................................................... 1 16 .......................... 808583 ..................................... Helical Gear ...................................................................................... 1 17 .......................... 808595 ..................................... Bearing Ball ....................................................................................... 1 18 .......................... 808592 ..................................... Washer .............................................................................................. 2 19 .......................... 808586 ..................................... Bushing ............................................................................................. 1 20 .......................... 808591 ..................................... Washer .............................................................................................. 1 21 .......................... 808596 ..................................... Bearing Ball ....................................................................................... 1 22 .......................... 808580 ..................................... Bevel Gear Set .................................................................................. 1 23 .......................... 808577 ..................................... Transmission Case ............................................................................ 1 24 .......................... 808602 ..................................... O-Ring ............................................................................................... 1 25 .......................... 808578 ..................................... Cover - Gear Box .............................................................................. 1 26 .......................... 808611 ..................................... Screw ................................................................................................ 8 27 .......................... 808609 ..................................... Seal ................................................................................................... 2 28 .......................... 808607 ..................................... Plug Drain ......................................................................................... 1 29 .......................... 050005-072 .............................. Screw ................................................................................................ 10 30 .......................... 808614 ..................................... Washer .............................................................................................. 12 31 .......................... 808613 ..................................... Screw ................................................................................................ 2 32 .......................... 808610 ..................................... Screw ................................................................................................ 3 33 .......................... 808590 ..................................... Washer .............................................................................................. 1 34 .......................... 808598 ..................................... Bearing Ball ....................................................................................... 1 35 .......................... 808589 ..................................... Shim .................................................................................................. 1 36 .......................... 808587 ..................................... Distance Washer ............................................................................... 1 37 .......................... 808608 ..................................... Cap .................................................................................................... 1 38 .......................... 808597 ..................................... Bearing Ball ....................................................................................... 1 39 .......................... 808605 ..................................... Circlip ................................................................................................ 1 40 .......................... 808600 ..................................... Seal ................................................................................................... 1 41 .......................... 808588 ..................................... Threaded Protection Shield ............................................................... 1 42 .......................... 808579 ..................................... Wheel Shaft ....................................................................................... 1 43 .......................... 808585 ..................................... Stud Wheel ........................................................................................ 7 44 .......................... 808606 ..................................... Plug Drain ......................................................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-3.1-2140

63

GEAR BOX 1 2

3

4 7 2

6

5

8

12 9 13

10

11

14 34 15

10

21 20 22 41 35 33 15

39

24

2

27 32 26

23

24 25 31

16 40

19

27 38 17

37 36

28

18 30 29 19

MP-2140-116 MP-3.1-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 11/05 M1.0-0000-00062 62A

GEAR BOX INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 812238 ..................................... Gear Box ................................................................................................ 1 1 ........................... 808612 ..................................... Screw ................................................................................................ 15 2 ........................... 805164 ..................................... Washer .............................................................................................. 25 3 ........................... 808593 ..................................... Turntable ............................................................................................ 1 4 ........................... 808616 ..................................... Pin ..................................................................................................... 1 5 ........................... 808603 ..................................... O-Ring ............................................................................................... 1 6 ........................... 808601 ..................................... Seal ................................................................................................... 1 7 ........................... 050005-026 .............................. Screw ................................................................................................ 2 8 ........................... 808581 ..................................... Gear Rim ........................................................................................... 1 9 ........................... 808604 ..................................... O-Ring ............................................................................................... 1 10 .......................... 808599 ..................................... Bearing Ball ....................................................................................... 2 11 .......................... 808582 ..................................... Pinion ................................................................................................ 1 12 .......................... 808584 ..................................... Nut ..................................................................................................... 1 13 .......................... 808583 ..................................... Helical Gear ...................................................................................... 1 14 .......................... 808595 ..................................... Bearing Ball ....................................................................................... 1 15 .......................... 808592 ..................................... Washer .............................................................................................. 2 16 .......................... 808586 ..................................... Bushing ............................................................................................. 1 17 .......................... 808591 ..................................... Washer .............................................................................................. 1 18 .......................... 808596 ..................................... Bearing Ball ....................................................................................... 1 19 .......................... 808580 ..................................... Bevel Gear Set .................................................................................. 1 20 .......................... 808577 ..................................... Transmission Case ............................................................................ 1 21 .......................... 808602 ..................................... O-Ring ............................................................................................... 1 22 .......................... 808578 ..................................... Cover - Gear Box .............................................................................. 1 23 .......................... 808611 ..................................... Screw ................................................................................................ 8 24 .......................... 808609 ..................................... Seal ................................................................................................... 2 25 .......................... 808607 ..................................... Plug Drain ......................................................................................... 1 26 .......................... 050005-072 .............................. Screw ................................................................................................ 10 27 .......................... 808614 ..................................... Washer .............................................................................................. 12 28 .......................... 808613 ..................................... Screw ................................................................................................ 2 29 .......................... 808610 ..................................... Screw ................................................................................................ 3 30 .......................... 808590 ..................................... Washer .............................................................................................. 1 31 .......................... 808598 ..................................... Bearing Ball ....................................................................................... 1 32 .......................... 808589 ..................................... Shim .................................................................................................. 1 33 .......................... 808587 ..................................... Distance Washer ............................................................................... 1 34 .......................... 808608 ..................................... Cap .................................................................................................... 1 35 .......................... 808597 ..................................... Bearing Ball ....................................................................................... 1 36 .......................... 808605 ..................................... Circlip ................................................................................................ 1 37 .......................... 808600 ..................................... Seal ................................................................................................... 1 38 .......................... 808588 ..................................... Threaded Protection Shield ............................................................... 1 39 .......................... 808579 ..................................... Wheel Shaft ....................................................................................... 1 40 .......................... 808585 ..................................... Stud Wheel ........................................................................................ 7 41 .......................... 808606 ..................................... Plug Drain ......................................................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-3.1-2140

01 REV. 11/05

63A

DRIVE MOTOR 1 1

1 5 5 2

3

3 3

6

5

3 5 5

4

7

5 7

5

7 7 8 7 5

9

1 1

MP-2140-088 MP-3.2-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05

64M1.0-0000-00064

DRIVE MOTOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 811852 ..................................... Drive Motor Assembly ............................................................................ 1 1 ........................... 816774 ..................................... Screw - Kit ......................................................................................... 1 2 ........................... 816775 ..................................... End Shield ......................................................................................... 1 3 ........................... 816768 ..................................... Pin - Kit .............................................................................................. 1 4 ................................. 816769 ...................................... Sensor Bearing ............................................................................ 1 5 ........................... 816776 ..................................... Armature (included 4) ........................................................................ 1 6 ........................... 814819 ..................................... Stator ................................................................................................ 1 7 ........................... 816771 ..................................... Terminal Block - Kit ............................................................................ 1 8 .............................................................................. Power Cable (see Section 4.1) .......................................................... 1 9 ........................... 816777 ..................................... End Shield ......................................................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-3.2-2140

01 REV. 05/05

65

Page intentionally left blank

Printed in Germany

66M1.0-0000-00066

SECTION 4

Printed in Germany

67

ELECTRICAL COMPARTMENT Part 1-2 11 8

10

7

6

12

5

5 9

4

3

2

14 13 13 14

5 16 3

19 21

18 1

15 3

17

20

22 MP-2140-060 MP-4.1-2140

68M1.0-0000-00068

MP-ESR4500-GB 06/04 • Printed in Germany

ELECTRICAL COMPARTMENT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 811866 ..................................... Compartment Tray .................................................................................. 1 050070-002 .............................. Screw ...................................................................................................... 5 050073-004 .............................. Spring Nut ............................................................................................... 5 2 ..................... 811206 ..................................... Canion Controller .................................................................................... 1 3 ..................... 050068-002 .............................. Nut .......................................................................................................... 12 4 ..................... 813873 ..................................... Plate ........................................................................................................ 1 5 ..................... 050068-003 .............................. Nut .......................................................................................................... 14 6 ..................... 811713 ..................................... Bracket ................................................................................................... 1 7 ..................... 811240 ..................................... Steering Controller .................................................................................. 1 8 ..................... 050067-022 .............................. Screw ...................................................................................................... 2 9 ..................... 807857 ..................................... Bracket ................................................................................................... 1 10 .................... 811213 ..................................... Traction Controller ................................................................................... 1 11 .................... 811215 ..................................... Hydraulic Controller ................................................................................ 1 12 .................... 804683-001 .............................. Cage Nut ................................................................................................. 1 13 .................... 050009-012 .............................. Washer ................................................................................................... 8 14 .................... 050006-024 .............................. Screw ...................................................................................................... 8 15 ....................................................................... Joystick and Emergency Disconnect Switch (see Section 4.6) ............. 1 16 .................... 812248 ..................................... Bracket ................................................................................................... 1 17 .................... 050003-014 .............................. Screw ...................................................................................................... 1 18 .................... 793288 ..................................... Clip .......................................................................................................... 1 19 .................... 050008-008 .............................. Nut .......................................................................................................... 1 20 .................... 813941-001 .............................. Fan Assembly ......................................................................................... 1 812246 ..................................... Fan .................................................................................................... 1 792880-001 .............................. Pin Housing ....................................................................................... 1 792882 ..................................... Pin Crimp .......................................................................................... 2 793090-001 .............................. Anti-Backout ...................................................................................... 1 21 .................... 050004-013 .............................. Screw ...................................................................................................... 4 22 .................... 050008-001 .............................. Nut .......................................................................................................... 4

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.1-2140

01 REV. 05/05

69

ELECTRICAL COMPARTMENT Part 1-2 10 7

9

6

5

11

4

4 8 3

2

13 12 12 13

15 3

18 20

17 1

14 3

16

19

21 MP-2140-117 MP-4.1-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 11/05 M1.0-0000-00068 68A

ELECTRICAL COMPARTMENT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 816266 ..................................... Compartment Tray .................................................................................. 1 050070-002 .............................. Screw ...................................................................................................... 5 050073-004 .............................. Spring Nut ............................................................................................... 5 2 ..................... 816823-004 .............................. Controller ................................................................................................ 1 3 ..................... 050068-002 .............................. Nut .......................................................................................................... 12 4 ..................... 050068-003 .............................. Nut .......................................................................................................... 12 5 ..................... 811713 ..................................... Bracket ................................................................................................... 1 6 ..................... 816264-002 .............................. Steering Controller .................................................................................. 1 7 ..................... 050005-060 .............................. Screw ...................................................................................................... 4 8 ..................... 807857 ..................................... Bracket ................................................................................................... 1 9 ..................... 811213 ..................................... Traction Controller ................................................................................... 1 10 .................... 811215 ..................................... Hydraulic Controller ................................................................................ 1 11 .................... 804683-001 .............................. Cage Nut ................................................................................................. 1 12 .................... 050009-012 .............................. Washer ................................................................................................... 8 13 .................... 050006-024 .............................. Screw ...................................................................................................... 8 14 ....................................................................... Joystick and Emergency Disconnect Switch (see Section 4.6) ............. 1 15 .................... 812248 ..................................... Bracket ................................................................................................... 1 16 .................... 050003-014 .............................. Screw ...................................................................................................... 1 17 .................... 793288 ..................................... Clip .......................................................................................................... 1 18 .................... 050008-008 .............................. Nut .......................................................................................................... 1 19 .................... 813941-001 .............................. Fan Assembly ......................................................................................... 1 812246 ..................................... Fan .................................................................................................... 1 792880-001 .............................. Pin Housing ....................................................................................... 1 792882 ..................................... Pin Crimp .......................................................................................... 2 793090-001 .............................. Anti-Backout ...................................................................................... 1 20 .................... 050004-013 .............................. Screw ...................................................................................................... 4 21 .................... 050008-001 .............................. Nut .......................................................................................................... 4

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.1-2140

02 REV. 11/05

69A

ELECTRICAL COMPARTMENT Part 2-2 22 2 21

23 3

19

22

22

21

22

4

1 A

21

21

2

5

19 20 C

6

B 7

9

13 E

D

14 16

10 11

17 22

15

18

12

8

15 22

21

21

27

22 21

24

A

8

B

22

30

22

C 21

D 21

25

29

22 E

26 21

21

22 28

MP-2140-061 MP-4.1-2140

70M1.0-0000-00070

MP-ESR4500-GB 06/04 • Printed in Germany

ELECTRICAL COMPARTMENT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 812316 ..................................... Air Stop ................................................................................................... 1 2 ..................... 050068-002 .............................. Nut .......................................................................................................... 3 3 ..................... 812318 ..................................... Sleeve ..................................................................................................... 1 4 ..................... 812317 ..................................... Clip .......................................................................................................... 1 5 ..................... 812324 ..................................... Battery Plug Assembly (DIN 160) ........................................................... 1 813241-076 .............................. Battery Plug Housing ........................................................................ 1 812334-007 .............................. Power Cable (B+) .............................................................................. 1 812334-008 .............................. Power Cable (B-) ............................................................................... 1 813742 ..................................... Battery Plug Assembly (SBE160) ........................................................... 1 806718-001 .............................. Battery Plug Housing ........................................................................ 1 812334-011 .............................. Power Cable (B+) .............................................................................. 1 812334-012 .............................. Power Cable (B-) ............................................................................... 1 813743 ..................................... Battery Plug Assembly (SBE 350 Australia) ........................................... 1 794493 ..................................... Battery Plug Housing ........................................................................ 1 812334-009 .............................. Power Cable (B+) .............................................................................. 1 812334-008 .............................. Power Cable (B-) ............................................................................... 1 808468 ..................................... Plate .................................................................................................. 1 813755 ..................................... Battery Plug Assembly (SBE 350 USA) ................................................. 1 796734 ..................................... Battery Plug Housing ........................................................................ 1 812334-013 .............................. Power Cable (B+) .............................................................................. 1 812334-014 .............................. Power Cable (B-) ............................................................................... 1 808468 ..................................... Plate .................................................................................................. 1 6 ..................... 050009-013 .............................. Washer ................................................................................................... AR 7 ..................... 050007-011 .............................. Screw (DIN 160) ..................................................................................... 4 050007-010 .............................. Screw (SBE160) ..................................................................................... 2 050005-063 .............................. Screw (SBE 350 Australia/SBE 350 USA) ............................................. 2 8 ..................... 050078-008 .............................. Blind Rivet Nut ........................................................................................ 6 9 ..................... 813222 ..................................... Module .................................................................................................... 1 10 .................... 811996-001 .............................. Relay Socket .......................................................................................... 2 11 .................... 050007-009 .............................. Screw ...................................................................................................... 2 12 .................... 811995-001 .............................. Relay ....................................................................................................... 2 13 .................... 806702 ..................................... Fuse Box ................................................................................................ 1 805818 ..................................... Spacer .................................................................................................... 2 806703-001 .............................. Fuse 15A ................................................................................................ AR 806703-002 .............................. Fuse 5A .................................................................................................. AR 14 .................... 050005-006 .............................. Screw ...................................................................................................... 2 15 .................... 050078-007 .............................. Blind Rivet Nut ........................................................................................ 5 16 .................... 793288 ..................................... Clip .......................................................................................................... 1 17 .................... 050003-014 .............................. Screw ...................................................................................................... 1 18 .................... 792880-003 .............................. Pin Housing ............................................................................................. 1 19 .................... 812323 ..................................... Copper Link ............................................................................................. 2 20 .................... 812322 ..................................... Copper Link ............................................................................................. 1 21 .................... 050009-018 .............................. Washer ................................................................................................... 10 22 .................... 050006-035 .............................. Screw ...................................................................................................... 10 23 .................... 812334-008 .............................. Power Cable (B-/DIN 160) ...................................................................... 1 812334-010 .............................. Power Cable (B-/SBE 350 Australia) ...................................................... 1 812334-012 .............................. Power Cable (B-/SBE160) ...................................................................... 1 812334-014 .............................. Power Cable (B-/SBE 350 USA) ............................................................. 1 24 .................... 812334-017 .............................. Power Cable (Pu) .................................................................................... 1 812334-003 .............................. Power Cable (Pu/Drive in Racking) ........................................................ 1 25 .................... 812334-016 .............................. Power Cable (Pv) .................................................................................... 1 812334-002 .............................. Power Cable (Pv/Drive in Racking) ........................................................ 1 26 .................... 812334-015 .............................. Power Cable (Pw) ................................................................................... 1 812334-001 .............................. Power Cable (Pw/Drive in Racking) ........................................................ 1 27 .................... 812334-006 .............................. Power Cable (Tu) .................................................................................... 1 28 .................... 812334-005 .............................. Power Cable (Tv) .................................................................................... 1 29 .................... 812334-004 .............................. Power Cable (Tw) .................................................................................... 1 30 .................... 812334-007 .............................. Power Cable (B+/DIN 160) ..................................................................... 1 812334-009 .............................. Power Cable (B+/SBE 350 Australia) ..................................................... 1 812334-011 .............................. Power Cable (B+/SBE160) ..................................................................... 1 812334-013 .............................. Power Cable (B+/SBE 350 USA) ............................................................ 1 Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.1-2140

01 REV. 05/05

71

ELECTRICAL COMPARTMENT Part 2-2 22 2 21

23 3

19

22

22

21

22

4

1 A

21

21

2

5

19 20 C

6

B 7

9

13 E

D

14 16

10 11

17 22

15

18

12

8

15 22

21

21

27

22 21

24

A

8

B

22

30

22

C 21

D 21

25

29

22 E

26 21

21

22 28

MP-2140-061 MP-4.1-2140

M1.0-0000-00070 70A

MP-ESR4500-GB 06/04 • Printed in Germany

ELECTRICAL COMPARTMENT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 812316 ..................................... Air Stop ................................................................................................... 1 2 ..................... 050068-002 .............................. Nut .......................................................................................................... 3 3 ..................... 812318 ..................................... Sleeve ..................................................................................................... 1 4 ..................... 812317 ..................................... Clip .......................................................................................................... 1 816096 ..................................... Plate ........................................................................................................ 1 5 ..................... 812324 ..................................... Battery Plug Assembly (DIN 160) ........................................................... 1 813241-076 .............................. Battery Plug Housing (included Contacts/Truck Side) ....................... 1 813241-065 .............................. Battery Socket Housing (included Contacts/Battery Side) ................ 1 812334-007 .............................. Power Cable (B+) .............................................................................. 1 812334-008 .............................. Power Cable (B-) ............................................................................... 1 813742 ..................................... Battery Plug Assembly (SBE160) ........................................................... 1 806718-001 .............................. Battery Plug Housing ........................................................................ 1 812334-011 .............................. Power Cable (B+) .............................................................................. 1 812334-012 .............................. Power Cable (B-) ............................................................................... 1 813743 ..................................... Battery Plug Assembly (SBE 350 blue) .................................................. 1 794493 ..................................... Battery Plug Housing ........................................................................ 1 812334-009 .............................. Power Cable (B+) .............................................................................. 1 812334-008 .............................. Power Cable (B-) ............................................................................... 1 808468 ..................................... Plate .................................................................................................. 1 813755 ..................................... Battery Plug Assembly (SBE 350 red) .................................................... 1 796734 ..................................... Battery Plug Housing ........................................................................ 1 812334-013 .............................. Power Cable (B+) .............................................................................. 1 812334-014 .............................. Power Cable (B-) ............................................................................... 1 808468 ..................................... Plate .................................................................................................. 1 6 ..................... 050009-013 .............................. Washer ................................................................................................... AR 7 ..................... 050007-011 .............................. Screw (DIN 160) ..................................................................................... 4 050007-010 .............................. Screw (SBE160) ..................................................................................... 2 050005-063 .............................. Screw (SBE 350 blue/SBE 350 red) ....................................................... 2 8 ..................... 050078-008 .............................. Blind Rivet Nut ........................................................................................ 6 9 ..................... 813222 ..................................... Module .................................................................................................... 1 10 .................... 811996-001 .............................. Relay Socket .......................................................................................... 2 11 .................... 050007-009 .............................. Screw ...................................................................................................... 2 12 .................... 811995-001 .............................. Relay ....................................................................................................... 2 13 .................... 816099 ..................................... Fuse Box ................................................................................................ 1 805818 ..................................... Spacer .................................................................................................... 2 806703-001 .............................. Fuse 15A ................................................................................................ AR 806703-002 .............................. Fuse 5A .................................................................................................. AR 14 .................... 050005-006 .............................. Screw ...................................................................................................... 2 15 .................... 050078-007 .............................. Blind Rivet Nut ........................................................................................ 5 16 .................... 793288 ..................................... Clip .......................................................................................................... 1 17 .................... 050003-014 .............................. Screw ...................................................................................................... 1 18 .................... 792880-003 .............................. Pin Housing ............................................................................................. 1 19 .................... 812323 ..................................... Copper Link ............................................................................................. 2 20 .................... 812322 ..................................... Copper Link ............................................................................................. 1 21 .................... 050009-018 .............................. Washer ................................................................................................... 10 22 .................... 050006-035 .............................. Screw ...................................................................................................... 10 23 .................... 812334-008 .............................. Power Cable (B-/DIN 160) ...................................................................... 1 812334-010 .............................. Power Cable (B-/SBE 350 blue) .............................................................. 1 812334-012 .............................. Power Cable (B-/SBE160) ...................................................................... 1 812334-014 .............................. Power Cable (B-/SBE 350 red) ............................................................... 1 24 .................... 812334-017 .............................. Power Cable (Pu) .................................................................................... 1 25 .................... 812334-016 .............................. Power Cable (Pv) .................................................................................... 1 26 .................... 812334-015 .............................. Power Cable (Pw) ................................................................................... 1 27 .................... 812334-006 .............................. Power Cable (Tu) .................................................................................... 1 28 .................... 812334-005 .............................. Power Cable (Tv) .................................................................................... 1 29 .................... 812334-004 .............................. Power Cable (Tw) .................................................................................... 1 30 .................... 812334-007 .............................. Power Cable (B+/DIN 160) ..................................................................... 1 812334-009 .............................. Power Cable (B+/SBE 350 blue) ............................................................. 1 812334-011 .............................. Power Cable (B+/SBE160) ..................................................................... 1 812334-013 .............................. Power Cable (B+/SBE 350 red) .............................................................. 1 Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.1-2140

02 REV. 11/05

71A

CONTACTOR

1

3

2

4 3

5 6

7 8

9 MP-2140-045 MP-4.4-2140

72M1.0-0000-00072

MP-ESR4500-GB 06/04 • Printed in Germany

CONTACTOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 813757 ..................................... Line Contactor ........................................................................................ 1 1 ........................... 120115 ..................................... Top Cover Fixing Screw .................................................................... 2 2 ........................... 805265 ..................................... Top Cover Moulding ........................................................................... 1 3 ........................... 120112 ..................................... Fixed Contact .................................................................................... 2 4 ........................... 794032 ..................................... Return Spring .................................................................................... 1 5 ........................... 120113 ..................................... Moving Contact (contain Index 7) ..................................................... 1 6 ........................... 120120 ..................................... Top Cover Base Moulding ................................................................. 1 7 ........................... 120629 ..................................... Moving Contact Plunger .................................................................... 1 8 ........................... 794026 ..................................... Coil and Frame .................................................................................. 1 9 ........................... 120638 ..................................... End Cap ............................................................................................ 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.4-2140

73

REACH SLOWDOWN

Chassi

1

2

Reach Carriage

3

11

8 8 7

7 9

4

10

6

12

6 5

MP-2140-059 MP-4.5-2140

74M1.0-0000-00074

MP-ESR4500-GB 06/04 • Printed in Germany

REACH SLOWDOWN INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 812870-001 .............................. Sensor Bracket (1.4t/420Ah) .................................................................. 1 812870-002 .............................. Sensor Bracket (1.4t/560Ah) .................................................................. 1 812870-003 .............................. Sensor Bracket (1.4t/700Ah) .................................................................. 1 812870-004 .............................. Sensor Bracket (1.4t/820Ah) .................................................................. 1 812870-005 .............................. Sensor Bracket (1.6t/420Ah) .................................................................. 1 812870-006 .............................. Sensor Bracket (1.6t/2.0t/560Ah) ........................................................... 1 812870-007 .............................. Sensor Bracket (1.6t/2.0t/700Ah) ........................................................... 1 812870-008 .............................. Sensor Bracket (1.6t/2.0t/820Ah) ........................................................... 1 2 ..................... 050003-061 .............................. Screw ...................................................................................................... AR 3* .................... 812361 ..................................... Bracket ................................................................................................... 1 4* .................... 811378-004 .............................. Sensor Assembly ................................................................................... 1 792880-003 .............................. Pin Housing ....................................................................................... 1 792882 ..................................... Pin Crimp .......................................................................................... 3 793090-003 .............................. Anti-Backout ...................................................................................... 1 5* .................... 811378-003 .............................. Sensor Assembly ................................................................................... 1 792880-002 .............................. Pin Housing ....................................................................................... 1 792882 ..................................... Pin Crimp .......................................................................................... 3 793090-002 .............................. Anti-Backout ...................................................................................... 1 6* .................... 050004-015 .............................. Screw ...................................................................................................... 4 7* .................... 050009-004 .............................. Washer ................................................................................................... 4 8* .................... 050008-001 .............................. Nut .......................................................................................................... 4 9* .................... 793288 ..................................... Clip .......................................................................................................... 2 10* ................... 050003-014 .............................. Screw ...................................................................................................... 2 11* ................... 050008-008 .............................. Nut .......................................................................................................... 2 12 .................... 050067-023 .............................. Screw ...................................................................................................... 2

* ..................... 812074 ..................................... Reach Sensor Assembly (included 3 - 11) ............................................. 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.5-2140

75

HGTS - LIFT SPEED REDUCTION

19

21 20 11

9

3 8

10

22

12 13

15

14

16

7 3 18

17

6

5

4

2

1

MP-2140-086 MP-4.5-2140

76M1.0-0000-00076

MP-ESR4500-GB 06/04 • Printed in Germany

HGTS - LIFT SPEED REDUCTION INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 050067-014 .............................. Screw ...................................................................................................... 4 2 ..................... 808096 ..................................... Cover ...................................................................................................... 1 3 ..................... 808038 ..................................... Spacer .................................................................................................... 4 4 ..................... 808026 ..................................... Bracket ................................................................................................... 1 5 ..................... 050068-012 .............................. Screw ...................................................................................................... 4 6 ..................... 808095 ..................................... Cover ...................................................................................................... 1 7 ..................... 807870 ..................................... Bracket ................................................................................................... 1 8 ..................... 050006-001 .............................. Screw ...................................................................................................... 2 9 ..................... 792991 ..................................... Microswitch (HGTS 12) .......................................................................... 1 10 .................... 803310 ..................................... Actuator .................................................................................................. 1 11 .................... 807541 ..................................... Plate ........................................................................................................ 1 12 .................... 050003-013 .............................. Screw ...................................................................................................... 1 13 .................... 793288 ..................................... Clip .......................................................................................................... 1 14 .................... 050008-008 .............................. Nut .......................................................................................................... 1 15 .................... 792881-002 .............................. Socket Housing ...................................................................................... 1 792883 ..................................... Socket Crimp .......................................................................................... 3 793091-002 .............................. Anti-Backout ........................................................................................... 1 16 .................... 050006-014 .............................. Screw ...................................................................................................... 1 17 .................... 061002-001 .............................. Clamp ...................................................................................................... 1 18 .................... 050008-008 .............................. Nut .......................................................................................................... 1

only for Freezer/Corrosion 19 .................... 796008 ..................................... Bracket ................................................................................................... 1 20 .................... 794590-001 .............................. Cable Assembly (inclusive 794611-001,792880-001, ............................. 1 792882,793090-001) 21 .......................... 794611-001 .............................. Heater ............................................................................................... 1 050004-042 .............................. Screw ...................................................................................................... 2 050008-011 .............................. Nut .......................................................................................................... 2 22 .......................... 792880-001 .............................. Pin Housing ....................................................................................... 1 792882 ..................................... Pin Insert ........................................................................................... 2 793090-001 .............................. Anti Backout ...................................................................................... 1 796173 ..................................... Heater Assembly (included 19 - 22) ........................................................ 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.5-2140

77

HGTS - LIFT SPEED REDUCTION

12

13 4

1

11 10

5

9 8

3

7 6 5 4

Mast 3

1 2

MP-2140-105 MP-4.5-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05 M1.0-0000-00076 76A

HGTS - LIFT SPEED REDUCTION INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 050083-001 .............................. Screw ...................................................................................................... 4 2 ..................... 815204 ..................................... Cover ...................................................................................................... 1 3 ..................... 808038 ..................................... Spacer .................................................................................................... 4 4 ..................... 793288 ..................................... Clip .......................................................................................................... 2 5 ..................... 050003-006 .............................. Screw ...................................................................................................... 2 6 ..................... 060014-094 .............................. Screw ...................................................................................................... 2 7 ..................... 815207 ..................................... Shim ........................................................................................................ AR 8 ..................... 815556 ..................................... Height Switch .......................................................................................... 1 9 ..................... 050003-014 .............................. Screw ...................................................................................................... 2 10 .................... 815208 ..................................... Plate (with Height Encoder) .................................................................... 1 815210 ..................................... Plate (without Height Encoder) ............................................................... 1 11 .................... 815209 ..................................... Shim (with Height Encoder) .................................................................... AR 815211 ..................................... Shim (without Height Encoder) ............................................................... AR 12 .................... 815205 ..................................... Cover ...................................................................................................... 1 13 ....................................................................... Height Encoder (see next Page) ............................................................. 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.5-2140

01 REV. 05/05

77A

HEIGHT ENCODER 13 11

29 7 2

30

8

6

5 16

3

17

4

18 15

19

10

22

20 1

23

21

25 14 9 24 31

26 27

12 37 28

32 36

37 32

37

35

33 38

34 MP-2140-093 MP-4.5-2140

78M1.0-0000-00078

MP-ESR4500-GB 06/04 • Printed in Germany

HEIGHT ENCODER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 808215 ..................................... Bracket ................................................................................................... 1 2 ..................... 793288 ..................................... Clip .......................................................................................................... 1 3 ..................... 050003-013 .............................. Screw ...................................................................................................... 1 4 ..................... 050008-008 .............................. Nut .......................................................................................................... 1 5 ..................... 808896 ..................................... Power Supply Assembly (included 6 & 7) .............................................. 1 6 ........................... 062535-006 .............................. Pin Housing ....................................................................................... 1 062536-001 .............................. Pin Insert ........................................................................................... 4 7 ........................... 792880-003 .............................. Pin Housing ....................................................................................... 1 792882 ..................................... Pin Insert ........................................................................................... 4 793090-003 .............................. Anti-Backout ...................................................................................... 1 8 ..................... 050004-009 .............................. Screw ...................................................................................................... 2 9 ..................... 050008-004 .............................. Nut .......................................................................................................... 2 10 .................... 050006-033 .............................. Screw ...................................................................................................... 2 11 .................... 808393 ..................................... Cable Guide ............................................................................................ 1 12 .................... 050006-023 .............................. Screw ...................................................................................................... 1 13 .................... 808733 ..................................... Blind Rivet Nut ........................................................................................ 2 14 .................... 050006-033 .............................. Screw ...................................................................................................... 2 15 .................... 808362 ..................................... Case ....................................................................................................... 1 16 .................... 808379 ..................................... Pin ........................................................................................................... 2 17 .................... 808410 ..................................... Bearing Ball ............................................................................................. 2 18 .................... 808378 ..................................... Pulley ...................................................................................................... 2 19 .................... 050009-014 .............................. Washer ................................................................................................... 2 20 .................... 050012-013 .............................. Ring Retaining ........................................................................................ 2 21 .................... 808361 ..................................... Pulley ...................................................................................................... 1 22 .................... 050017-018 .............................. Screw ...................................................................................................... 1 23 .................... 055002-026 .............................. Bearing Ball ............................................................................................. 1 24 .................... 050012-069 .............................. Ring Retaining ........................................................................................ 1 25 .................... 808908 ..................................... Washer ................................................................................................... 1 26 .................... 050012-070 .............................. Ring Retaining ........................................................................................ 1 27 .................... 808380 ..................................... Plate ........................................................................................................ 1 28 .................... 127785 ..................................... Encoder PCP .......................................................................................... 1 29 .................... 808217 ..................................... Bolt .......................................................................................................... 1 30 .................... 050000-087 .............................. Pin ........................................................................................................... 1 31 .................... 808386 ..................................... Wire Rope ............................................................................................... 1 32 .................... 808826 ..................................... Slide Piece .............................................................................................. 2 808884 ..................................... Tape ........................................................................................................ 2 051051-004 .............................. Cable Tie ................................................................................................. 1 33 .................... 807303 ..................................... Spring ..................................................................................................... 1 34 .................... 808216 ..................................... Bracket ................................................................................................... 1 35 .................... 050006-022 .............................. Screw ...................................................................................................... 1

808904 ..................................... Height EncoderMain Assembly (included 1 - 9 & 14 - 28) ....................... 1 808363 ..................................... Height Encoder Assembly (included 15 - 28) ......................................... 1

only for Freezer/Corrosion 36 .................... 796229 ..................................... Cable Assembly (included 37 & 38) ....................................................... 1 050004-042 .............................. Screw ...................................................................................................... 6 37 .......................... 794611-004 .............................. Heater ............................................................................................... 3 38 .......................... 792880-001 .............................. Pin Housing ....................................................................................... 1 792882 ..................................... Pin Insert ........................................................................................... 2 793090-001 .............................. Anti Backout ...................................................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.5-2140

79

HEIGHT ENCODER

15 1 3

5

2

4 8

7

6

9

13

14

11 10

12

MP-2140-104 MP-4.5-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05 M1.0-0000-00078 78A

HEIGHT ENCODER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 127704 ..................................... Bracket ................................................................................................... 1 2 ..................... 060038-003 .............................. Pin ........................................................................................................... 1 3 ..................... 127707 ..................................... Bracket ................................................................................................... 1 4 ..................... 127684 ..................................... Spring ..................................................................................................... 1 5 ..................... 129208 ..................................... Wheel ...................................................................................................... 1 6 ..................... 061085-001 .............................. Clip .......................................................................................................... 1 7 ..................... 816019 ..................................... Senor Bearing Assembly ........................................................................ 1 808123-003 .............................. Pin Housing ....................................................................................... 1 792882 ..................................... Pin Insert ........................................................................................... 4 793090-003 .............................. Anti-Backout ...................................................................................... 1 8 ..................... 128898 ..................................... Washer ................................................................................................... 1 9 ..................... 060014-094 .............................. Screw ...................................................................................................... 1 10 .................... 128888 ..................................... Gasket .................................................................................................... 1 11 .................... 128912 ..................................... Retainer .................................................................................................. 1 12 .................... 060014-008 .............................. Screw ...................................................................................................... 1 13 .................... 125256 ..................................... Retainer .................................................................................................. 1 14 .................... 815601 ..................................... Heater ..................................................................................................... 1 803448-005 .............................. Pin Housing ............................................................................................. 2 803448-004 .............................. Pin Insert ................................................................................................ 2 15 .................... 060015-123 .............................. Screw ...................................................................................................... 2

815557 ..................................... Height Encoder Assembly (included 1 - 12) ........................................... 1 815606 ..................................... Height Encoder Assembly (Freezer/Corrosion/included 1 - 14) ............. 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.5-2140

02 REV. 11/05

79A

MAST WIRING

9

Free Lift Cylinder

8

4

4 7

5 Tilt and Sideshift

6 4 3

Reach Carriage

1 2

5

MP-2140-091 MP-4.5-2140

80M1.0-0000-00080

MP-ESR4500-GB 06/04 • Printed in Germany

MAST WIRING INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 061002-001 .............................. Clamp (6-way) ........................................................................................ 1 061002-008 .............................. Clamp (10-way) ...................................................................................... 9 2 ..................... 050006-013 .............................. Screw ...................................................................................................... 1 3 ..................... 050008-008 .............................. Nut .......................................................................................................... 1 4 ..................... 052076-001 .............................. Clamp (6-way) ........................................................................................ 3 052076-002 .............................. Clamp (10-way) ...................................................................................... 3 5 ..................... 050071-035 .............................. Screw ...................................................................................................... 2 6 ..................... 050068-003 .............................. Nut .......................................................................................................... 1 7 ..................... 122914 ..................................... Spring ..................................................................................................... 1 107204 ..................................... Cable Grip (6-way) ................................................................................. 1 105449 ..................................... Cable Grip (10-way) ................................................................................ 1 8 ..................... 807303 ..................................... Spring ..................................................................................................... 1 9 ..................... 810214-*** ............................... Cable (6-way/see next Page) .................................................................. 1 810215-*** ............................... Cable (10-way/see next Page) ................................................................ 1 051051-009 .............................. Cable Tie ................................................................................................. 9 Not shown 810244 ..................................... Clamp ...................................................................................................... 1 050006-035 .............................. Screw ...................................................................................................... 1 808089 ..................................... Cable Assembly (Chassis - Mast) .......................................................... 1 061002-008 .............................. Clamp ...................................................................................................... 1 061002-001 .............................. Clamp ...................................................................................................... 1 050006-013 .............................. Screw ...................................................................................................... 2 050008-008 .............................. Nut .......................................................................................................... 2 810244 ..................................... Clamp ...................................................................................................... 1 050006-035 .............................. Screw ...................................................................................................... 1 792880-006 .............................. Pin Housing (Reach Carriage) ................................................................ 1 792882 ..................................... Pin Insert ................................................................................................ AR 793222 ..................................... Blanking Pin ............................................................................................ AR 793090-006 .............................. Anti-Backout ........................................................................................... 1 793288 ..................................... Clip .......................................................................................................... 1 050003-013 .............................. Screw ...................................................................................................... 1 792881-004 .............................. Pin Housing (6-way/Fork Carriage/Mast Side) ....................................... 1 792881-006 .............................. Pin Housing (10-way/Fork Carriage/Mast Side) ...................................... 1 792883 ..................................... Pin Insert ................................................................................................ AR 793091-004 .............................. Anti-Backout (6-way) .............................................................................. 1 793091-006 .............................. Anti-Backout (10-way) ............................................................................ 1 793217-018 .............................. Connector ............................................................................................... 1 792880-004 .............................. Pin Housing (6-way/Fork Carriage/Solenoid Side) ................................. 1 792880-006 .............................. Pin Housing (10-way/Fork Carriage/Solenoid Side) ................................ 1 792882 ..................................... Pin Insert ................................................................................................ AR 793222 ..................................... Blanking Pin ............................................................................................ AR 793090-004 .............................. Anti-Backout (6-way) .............................................................................. 1 793090-006 .............................. Anti-Backout (10-way) ............................................................................ 1 793288 ..................................... Clip .......................................................................................................... 1 050003-013 .............................. Screw ...................................................................................................... 1 050008-008 .............................. Nut .......................................................................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.5-2140

01 REV. 05/05

81

MAST WIRING

Position 9

Position 9

Collapsed Height

810214-001

810215-001

2022mm

810214-002

810215-002

2172mm

810214-003

810215-003

2322mm

810214-004

810215-004

2472mm

810214-005

810215-005

2572mm

810214-006

810215-006

2772mm

810214-007

810215-007

2922mm

810214-008

810215-008

3042mm

810214-009

810215-009

3192mm

810214-010

810215-010

3347mm

810214-011

810215-011

3492mm

810214-012

810215-012

3692mm

810214-013

810215-013

3842mm

810214-014

810215-014

3952mm

810214-015

810215-015

4252mm

810214-016

810215-016

4452mm Tab018gb

MP-4.5-2140

82M1.0-0000-00082

MP-ESR4500-GB 06/04 • Printed in Germany

Page intentionally left blank

Printed in Germany

83

JOYSTICK AND EMERGENCY DISCONNECT SWITCH 19 17

18

25

9 15

24 A

14

23

10 22 7 6 21

1

8

2 13

11 31

6

3

12 A

16 27

20

28

4 26

19

30

5

29

MP-2140-044 MP-4.6-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05

84M1.0-0000-00084

JOYSTICK AND EMERGENCY DISCONNECT SWITCH INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 812213 ..................................... Bracket ................................................................................................... 1 2 ..................... 804863-001 .............................. Cage Nut ................................................................................................. 3 3 ..................... 050068-003 .............................. Nut .......................................................................................................... 3 4 ........................................................................ Directional Switch/Horn Button (see next Page) ..................................... 1 5 ..................... 050006-032 .............................. Screw ...................................................................................................... 2 050009-018 .............................. Washer ................................................................................................... 2 6 ..................... 807037 ..................................... Joystick Assembly (Pot) ......................................................................... AR 792880-003 .............................. Pin Housing ....................................................................................... AR 792882 ..................................... Pin Insert ........................................................................................... AR 793090-003 .............................. Anti-Backout ...................................................................................... AR 7 ..................... 050006-024 .............................. Screw ...................................................................................................... AR 8 ..................... 050008-015 .............................. Nut .......................................................................................................... AR 9 ..................... 807523-001 .............................. Joystick & Label/Lift ................................................................................ 1 807523-002 .............................. Joystick & Label/Tilt ................................................................................ 1 807523-003 .............................. Joystick & Label/Reach .......................................................................... 1 807523-004 .............................. Joystick & Label/Load Stabilizer ............................................................. 1 807523-005 .............................. Joystick & Label/Upender ....................................................................... 1 807523-006 .............................. Joystick & Label/Sideshift ....................................................................... 1 807523-007 .............................. Joystick & Label/Fork Arm Spread ......................................................... 1 807523-008 .............................. Joystick & Label/Clamp .......................................................................... 1 807523-009 .............................. Joystick & Label/Rotate .......................................................................... 1 807523-010 .............................. Joystick & Label/Push/Pull ..................................................................... 1 10 .................... 791423-002 .............................. Joystick Hole Plug .................................................................................. 1 11 .................... 793288 ..................................... Clip .......................................................................................................... AR 12 .................... 050003-013 .............................. Screw ...................................................................................................... AR 13 .................... 050008-008 .............................. Nut .......................................................................................................... AR 14 .................... 802817 ..................................... Fuse Holder ............................................................................................ 1 050008-030 .............................. Nut .......................................................................................................... 2 050009-024 .............................. Washer ................................................................................................... 2 15 .................... 050004-014 .............................. Screw ...................................................................................................... 2 16 .................... 050008-001 .............................. Nut .......................................................................................................... 2 17 .................... 812320 ..................................... Copper Link ............................................................................................. 1 18 .................... 806720-001 .............................. Fuse ........................................................................................................ 1 19 .................... 050006-031 .............................. Screw ...................................................................................................... 2 20 .................... 813758 ..................................... Emergency Disconnect Switch (included 19) ......................................... 1 21 .................... 813378 ..................................... Seal ......................................................................................................... 1 22 .................... 812128 ..................................... Bracket ................................................................................................... 1 23 .................... 050009-008 .............................. Washer ................................................................................................... 2 24 .................... 050006-013 .............................. Screw ...................................................................................................... 2 25 .................... 812126 ..................................... Actuator-Emergency Disconnect Switch ................................................ 1 26 ....................................................................... Line Contactor (see Section 4.4) ............................................................ 1 27 .................... 050009-007 .............................. Washer ................................................................................................... 4 28 .................... 050006-008 .............................. Screw ...................................................................................................... 4 29 .................... 812321 ..................................... Copper Link ............................................................................................. 1 30 .................... 813382 ..................................... Heater Assembly (Freezer/Corrosion-Emergency Disconnect Switch) .. 1 813381 ..................................... Bracket .............................................................................................. 1 050004-044 .............................. Screw ................................................................................................ 2 050004-042 .............................. Screw (Heater) .................................................................................. 2 050008-011 .............................. Nut (Heater) ...................................................................................... 2 794590-001 .............................. Cable Assembly ................................................................................ 1 794611-001 ............................... Heater .......................................................................................... 1 792880-001 ............................... Pin Housing ................................................................................. 1 792882 ...................................... Pin Insert ..................................................................................... 2 793090-001 ............................... Anti Backout ................................................................................ 1 31 .................... 050008-024 .............................. Nut .......................................................................................................... 2 not shown 793217-007 .............................. Switch (6th Function Valve) ..................................................................... 1 796488 ..................................... Cable Assembly (6th Function Valve) ..................................................... 1 051051-009 .............................. Cable Ties (6th Function Valve) .............................................................. 5 796735 ..................................... Label (6th Function Valve) ....................................................................... 1 Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.6-2140

01 REV. 05/05

85

JOYSTICK AND EMERGENCY DISCONNECT SWITCH

MP-2140-114 MP-4.6-2140

MP-ESR4500-GB 06/04 • Printed in Germany

02 REV. 11/05 M1.0-0000-00084 84A

JOYSTICK AND EMERGENCY DISCONNECT SWITCH INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 816978 ..................................... Bracket ................................................................................................... 1 050067-022 .............................. Screw ...................................................................................................... 2 050068-003 .............................. Nut .......................................................................................................... 2 2 ..................... 804863-001 .............................. Cage Nut ................................................................................................. 3 3 ..................... 050078-003 .............................. Blind Rivet Nut ........................................................................................ 4 4 ..................... 816679 ..................................... Bracket ................................................................................................... 1 5 ..................... 050067-014 .............................. Screw ...................................................................................................... 4 6 ..................... 816221 ..................................... Joystick Assembly (Pot) ......................................................................... AR 792880-003 .............................. Pin Housing ............................................................................................. AR 792882 ..................................... Pin Insert ................................................................................................ AR 793090-003 .............................. Anti-Backout ........................................................................................... AR 7 ..................... 050005-049 .............................. Screw ...................................................................................................... AR 8 ..................... 807523-001 .............................. Joystick & Label/Lift ................................................................................ 1 807523-002 .............................. Joystick & Label/Tilt ................................................................................ 1 807523-003 .............................. Joystick & Label/Reach .......................................................................... 1 807523-004 .............................. Joystick & Label/Load Stabilizer ............................................................. 1 807523-005 .............................. Joystick & Label/Upender ....................................................................... 1 807523-006 .............................. Joystick & Label/Sideshift ....................................................................... 1 807523-007 .............................. Joystick & Label/Fork Arm Spread ......................................................... 1 807523-008 .............................. Joystick & Label/Clamp .......................................................................... 1 807523-009 .............................. Joystick & Label/Rotate .......................................................................... 1 807523-010 .............................. Joystick & Label/Push/Pull ..................................................................... 1 9 ..................... 791423-002 .............................. Joystick Hole Plug .................................................................................. 1 10 .................... 793288 ..................................... Clip .......................................................................................................... AR 11 .................... 050003-013 .............................. Screw ...................................................................................................... AR 12 .................... 050008-008 .............................. Nut .......................................................................................................... AR 13 .................... 802817 ..................................... Fuse Holder ............................................................................................ 1 050008-030 .............................. Nut .......................................................................................................... 2 050009-024 .............................. Washer ................................................................................................... 2 14 .................... 050004-014 .............................. Screw ...................................................................................................... 2 15 .................... 050008-001 .............................. Nut .......................................................................................................... 2 16 .................... 812320 ..................................... Copper Link ............................................................................................. 1 17 .................... 806720-001 .............................. Fuse ........................................................................................................ 1 18 .................... 050006-032 .............................. Screw ...................................................................................................... 2 19 .................... 813758 ..................................... Emergency Disconnect Switch (included 19) ......................................... 1 20 .................... 813378 ..................................... Seal ......................................................................................................... 1 21 .................... 812128 ..................................... Bracket ................................................................................................... 1 22 .................... 050009-008 .............................. Washer ................................................................................................... 2 23 .................... 050006-013 .............................. Screw ...................................................................................................... 2 24 .................... 812126 ..................................... Actuator-Emergency Disconnect Switch ................................................ 1 25 ....................................................................... Line Contactor (see Section 4.4) ............................................................ 1 26 .................... 050009-007 .............................. Washer ................................................................................................... 4 27 .................... 050006-008 .............................. Screw ...................................................................................................... 4 28 .................... 812321 ..................................... Copper Link ............................................................................................. 1 29 .................... 814958 ..................................... Fuse Holder ............................................................................................ 1 30 .................... 050005-001 .............................. Screw ...................................................................................................... 1 31 .................... 814995-002 .............................. Fuse ........................................................................................................ 1 32 .................... 813382 ..................................... Heater Assembly (Freezer/Corrosion-Emergency Disconnect Switch) .. 1 813381 ..................................... Bracket .............................................................................................. 1 050004-044 .............................. Screw ................................................................................................ 2 050004-042 .............................. Screw (Heater) .................................................................................. 2 050008-011 .............................. Nut (Heater) ...................................................................................... 2 794590-001 .............................. Cable Assembly ................................................................................ 1 794611-001 ............................... Heater .......................................................................................... 1 792880-001 ............................... Pin Housing ................................................................................. 1 792882 ...................................... Pin Insert ..................................................................................... 2 793090-001 ............................... Anti Backout ................................................................................ 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.6-2140

02 REV. 11/05

85A

JOYSTICK AND EMERGENCY DISCONNECT SWITCH

MP-2140-114 MP-ESR4500-GB 06/04 • Printed in Germany

02 REV. 11/05 M1.0-0000-00086 86A

JOYSTICK AND EMERGENCY DISCONNECT SWITCH INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

33 .................... 816980 ..................................... Bracket ................................................................................................... 1 34 .................... 816609-001 .............................. Dual-Axis Control .................................................................................... 1 35 .................... 816609-002 .............................. Dual-Axis Control (4 - Dual-Axis Control) ............................................... 1 816609-003 .............................. Dual-Axis Control (5 - Dual-Axis Control) ............................................... 1 069604-001 .............................. Label; Lift/Reach ..................................................................................... 1 069604-002 .............................. Label; Sideshift/Tilt .................................................................................. 1 069604-003 .............................. Label; Sideshift/Tilt/Load Stabilizer .......................................................... 1 069604-004 .............................. Label; Sideshift/Tilt/Rotate ....................................................................... 1 069604-005 .............................. Label; Sideshift/Tilt/Clamp ....................................................................... 1 069604-006 .............................. Label; Sideshift/Tilt/Fork Arm Spread ...................................................... 1 069604-007 .............................. Label; Sideshift/Tilt/Push - Pull ................................................................ 1 069604-008 .............................. Label; Sideshift/Tilt/Upender .................................................................... 1 36 .................... 050005-001 .............................. Screw ...................................................................................................... 8 not shown 816221 ..................................... Joystick Assembly (Pot - 6th Function Valve) ......................................... 1 050005-049 .............................. Screw ...................................................................................................... 4 814475 ..................................... Cable Assembly (6th Function Valve) ..................................................... 1 051051-009 .............................. Cable Ties (6th Function Valve) .............................................................. 5 796735 ..................................... Label (6th Function Valve) ....................................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

02 REV. 11/05

87A

DIRECTIONAL SWITCH/HORN BUTTON 20

24

23

25

24

27

17 1

16

4

8

7

6 26

24

3 10

5

4 17 22

19

9 12 4

11

12

18

7 10

15 21

8 6

2 4

9

13 14 MP-2140-043 MP-4.6-2140

88M1.0-0000-00088

MP-ESR4500-GB 06/04 • Printed in Germany

DIRECTIONAL SWITCH/HORN BUTTON INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 806676 ..................................... Bracket ................................................................................................... 1 2 ..................... 806679 ..................................... Bracket ................................................................................................... 1 3 ..................... 050003-014 .............................. Screw ...................................................................................................... 2 4 ..................... 050008-008 .............................. Nut .......................................................................................................... 7 5 ..................... 806746 ..................................... Horn Button ............................................................................................. 1 6 ..................... 806677 ..................................... Shaft ........................................................................................................ 2 7 ..................... 050001-013 .............................. Pin Split ................................................................................................... 2 8 ..................... 792991 ..................................... Microswitch ............................................................................................. 3 9 ..................... 050006-001 .............................. Screw ...................................................................................................... 6 10 .................... 050008-002 .............................. Nut .......................................................................................................... 6 11 .................... 050005-001 .............................. Screw ...................................................................................................... 1 12 .................... 050008-001 .............................. Nut .......................................................................................................... 3 13 .................... 793288 ..................................... Clip .......................................................................................................... 3 14 .................... 050003-015 .............................. Screw ...................................................................................................... 3 15 .................... 050009-007 .............................. Washer ................................................................................................... 2 16 .................... 803310 ..................................... Actuator Roller Arm ................................................................................. 2 17 .................... 050005-058 .............................. Screw ...................................................................................................... 2 18 .................... 806742 ..................................... Spring Roller ........................................................................................... 1 19 .................... 050005-002 .............................. Screw ...................................................................................................... 2 050009-003 .............................. Washer ................................................................................................... 4 20 .................... 806745 ..................................... Directional Lever ..................................................................................... 1 21 .................... 051064-006 .............................. Spring ..................................................................................................... 1 22 .................... 050009-012 .............................. Washer ................................................................................................... 2

only for Freezer/Corrosion

23 .................... 794572-002 .............................. Bracket ................................................................................................... 1 24 .................... 794611-001 .............................. Heater ..................................................................................................... 3 050004-042 .............................. Screw ...................................................................................................... 6 050008-011 .............................. Nut .......................................................................................................... 6 25 .................... 813702 ..................................... Bracket (Directional Lever) ..................................................................... 1 26 .................... 796004 ..................................... Bracket (Horn Button) ............................................................................. 1 27 .................... 792880-001 .............................. Pin Housing ............................................................................................. 1 792882 ..................................... Pin Insert ................................................................................................ 2 793090-001 .............................. Anti Backout ............................................................................................ 1 793288 ..................................... Clip .......................................................................................................... 1 050003-015 .............................. Screw ...................................................................................................... 1 050008-008 .............................. Nut .......................................................................................................... 1 796003-001 .............................. Cable Assembly (included 794611-001, 792880-001, 792882, ............... 1 793090-001) 813701 ..................................... Heater Assembly (included 23-27) ......................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.6-2140

89

DIRECTIONAL SWITCH/HORN BUTTON

MP-2140-113 MP-4.6-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 11/05 M1.0-0000-00088 88A

DIRECTIONAL SWITCH/HORN BUTTON INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 815017 ..................................... Bracket ................................................................................................... 1 050006-032 .............................. Screw ...................................................................................................... 2 050008-024 .............................. Nut .......................................................................................................... 2 050009-018 .............................. Washer ................................................................................................... 2 2 ..................... 806679 ..................................... Bracket ................................................................................................... 1 3 ..................... 050003-014 .............................. Screw ...................................................................................................... 2 4 ..................... 050008-008 .............................. Nut .......................................................................................................... 7 5 ..................... 806746 ..................................... Horn Button ............................................................................................. 1 6 ..................... 806677 ..................................... Shaft ........................................................................................................ 2 7 ..................... 050001-013 .............................. Pin Split ................................................................................................... 2 8 ..................... 792991 ..................................... Microswitch ............................................................................................. 3 9 ..................... 050006-001 .............................. Screw ...................................................................................................... 6 10 .................... 050008-002 .............................. Nut .......................................................................................................... 6 11 .................... 050005-001 .............................. Screw ...................................................................................................... 1 12 .................... 050008-001 .............................. Nut .......................................................................................................... 3 13 .................... 793288 ..................................... Clip .......................................................................................................... 3 14 .................... 050003-015 .............................. Screw ...................................................................................................... 3 15 .................... 050009-007 .............................. Washer ................................................................................................... 2 16 .................... 815922 ..................................... Plate ........................................................................................................ 2 17 .................... 050009-003 .............................. Washer ................................................................................................... 2 18 .................... 815655 ..................................... Spring Roller ........................................................................................... 1 19 .................... 050005-002 .............................. Screw ...................................................................................................... 2 20 .................... 806745 ..................................... Directional Lever ..................................................................................... 1 21 .................... 051064-006 .............................. Spring ..................................................................................................... 1 22 .................... 050009-012 .............................. Washer ................................................................................................... 2

only for Freezer/Corrosion

23 .................... 794572-002 .............................. Bracket ................................................................................................... 1 24 .................... 794611-001 .............................. Heater ..................................................................................................... 3 050004-042 .............................. Screw ...................................................................................................... 6 050008-011 .............................. Nut .......................................................................................................... 6 25 .................... 813702 ..................................... Bracket (Directional Lever) ..................................................................... 1 26 .................... 796004 ..................................... Bracket (Horn Button) ............................................................................. 1 27 .................... 792880-001 .............................. Pin Housing ............................................................................................. 1 792882 ..................................... Pin Insert ................................................................................................ 2 793090-001 .............................. Anti Backout ............................................................................................ 1 793288 ..................................... Clip .......................................................................................................... 1 050003-015 .............................. Screw ...................................................................................................... 1 050008-008 .............................. Nut .......................................................................................................... 1 796003-001 .............................. Cable Assembly (included 794611-001, 792880-001, 792882, ............... 1 793090-001) 813701 ..................................... Heater Assembly (included 23-27) ......................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.6-2140

01 REV. 11/05

89A

FLOORPLATE

2

1 13

12 14

15

2

18

Chassis 17

17

16

4

8 7

3

9

11

8

10 11 10

6

4

5

Drive Frame

MP-2140-030 MP-4.6-2140

90M1.0-0000-00090

MP-ESR4500-GB 06/04 • Printed in Germany

FLOORPLATE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1* .................... 811924 ..................................... Floor Mat ................................................................................................. 1 2 ..................... 050071-036 .............................. Screw ...................................................................................................... 2 3* .................... 811923 ..................................... Floorplate ................................................................................................ 1 4 ..................... 060102-001 .............................. Lug Nut ................................................................................................... 2 5 ..................... 812998 ..................................... Bracket ................................................................................................... 1 6 ..................... 050067-022 .............................. Screw ...................................................................................................... 1 7* .................... 793333 ..................................... Lug Nut ................................................................................................... 2 8* .................... 050009-013 .............................. Washer ................................................................................................... 2 9* .................... 050005-062 .............................. Screw ...................................................................................................... 2 10 .................... 812346 ..................................... Spacer .................................................................................................... 2 11 .................... 055058-003 .............................. Buffer ...................................................................................................... 2 12* ................... 806476 ..................................... Accelerator Pedal .................................................................................... 1 13* ................... 104215 ..................................... Pedal Rubber .......................................................................................... 1 14* ................... 793226 ..................................... Buffer ...................................................................................................... 1 15* ................... 050008-015 .............................. Nut .......................................................................................................... 1 16* ................... 807278 ..................................... Pin ........................................................................................................... 1 17* ................... 055084-010 .............................. Bush ........................................................................................................ 2 18* ................... 050000-056 .............................. Pin ........................................................................................................... 2

* ..................... 811922 ..................................... Floorplate & Pedal Assembly (included 1, 3, 7 - 9, 12 - 18) ..................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.6-2140

91

ACCELERATOR

9

23

10

22

25

12

14

11

27

24 17

13 26 25

21 20

18 19

8

15

12 16

7 6

5 1

4 2

3

MP-2140-042 MP-4.6-2140

92M1.0-0000-00092

MP-ESR4500-GB 06/04 • Printed in Germany

ACCELERATOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1* .................... 050012-030 .............................. Circlip ...................................................................................................... 1 2* .................... 793473 ..................................... Roller ...................................................................................................... 1 3* .................... 042053-020 .............................. Bush ........................................................................................................ 2 4* .................... 793558 ..................................... Lever ....................................................................................................... 1 5* .................... 042053-018 .............................. Bush ........................................................................................................ 2 6* .................... 793562 ..................................... Spring ..................................................................................................... 1 7* .................... 793561 ..................................... Collar Drive ............................................................................................. 1 8* .................... 050000-069 .............................. Split Cotter Pin ........................................................................................ 1 9* .................... 795572 ..................................... Bracket ................................................................................................... 1 10* ................... 795796 ..................................... Potentiometer Assembly ......................................................................... 1 792880-003 .............................. Pin Housing ....................................................................................... 1 792882 ..................................... Pin Crimp .......................................................................................... 3 793090-003 .............................. Anti Backout ...................................................................................... 1 11* ................... 050009-002 .............................. Washer ................................................................................................... 2 12* ................... 050006-001 .............................. Screw ...................................................................................................... 4 13* ................... 793226 ..................................... Buffer ...................................................................................................... 1 14* ................... 050008-015 .............................. Nut .......................................................................................................... 1 15* ................... 792991 ..................................... Microswitch ............................................................................................. 1 16* ................... 803310 ..................................... Actuator Roller Arm ................................................................................. 1 17* ................... 050008-002 .............................. Nut .......................................................................................................... 2 050009-002 .............................. Washer ................................................................................................... 1 18* ................... 793288 ..................................... Clip .......................................................................................................... 2 19* ................... 050003-013 .............................. Screw ...................................................................................................... 2 20* ................... 050008-008 .............................. Nut .......................................................................................................... 2 21 .................... 050006-035 .............................. Screw ...................................................................................................... 2 22 .................... 050008-024 .............................. Nut .......................................................................................................... 2

* ..................... 807751-001 .............................. Accelerator (included 1-20) ..................................................................... 1

only for Freezer/Corrosion

23 .................... 796009 ..................................... Bracket ................................................................................................... 1 24 .................... 796010 ..................................... Bracket ................................................................................................... 1 25 .................... 794611-001 .............................. Heater ..................................................................................................... 2 050004-042 .............................. Screw ...................................................................................................... 4 050008-011 .............................. Nut .......................................................................................................... 4 26 .................... 792880-001 .............................. Pin Housing ............................................................................................. 1 792882 ..................................... Pin Insert ................................................................................................ 2 793090-001 .............................. Anti Backout ............................................................................................ 1 793288 ..................................... Clip .......................................................................................................... 1 050003-015 .............................. Screw ...................................................................................................... 1 050008-008 .............................. Nut .......................................................................................................... 1 27 .................... 794591-001 .............................. Cable Assembly (included 794611-001, 792880-001, 792882, ............... 1 793090-001) 796013 ..................................... Heater Assembly (included 23-27) ......................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.6-2140

01 REV. 05/05

93

SAFETY PEDAL 19 21 20

1

22

23

3 2

12

13 4

7

16 9 10

11 6

8 6

9

17

14 5 5 15

18 MP-2140-040 MP-4.6-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05

94M1.0-0000-00094

SAFETY PEDAL INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 806934 ..................................... Pedal Rubber .......................................................................................... 1 2 ..................... 810482 ..................................... Lever ....................................................................................................... 1 3 ..................... 050071-019 .............................. Screw ...................................................................................................... 2 4 ..................... 810483 ..................................... Bushing ................................................................................................... 1 5 ..................... 808932 ..................................... Screw ...................................................................................................... 2 6 ..................... 050008-015 .............................. Nut .......................................................................................................... 2 7 ..................... 807048 ..................................... Spring ..................................................................................................... 1 8 ..................... 051058-010 .............................. Bushing ................................................................................................... 2 9 ..................... 792991 ..................................... Microswitch ............................................................................................. 1 803310 ..................................... Actuator .................................................................................................. 1 10 .................... 050004-036 .............................. Screw ...................................................................................................... 2 11 .................... 807541 ..................................... Plate ........................................................................................................ 1 12 .................... 050003-013 .............................. Screw ...................................................................................................... 2 13 .................... 793288 ..................................... Clip .......................................................................................................... 2 14 .................... 050008-008 .............................. Nut .......................................................................................................... 2 15 .................... 810480 ..................................... Bracket ................................................................................................... 1 16 .................... 810469 ..................................... Plate ........................................................................................................ 1 17 .................... 050067-037 .............................. Screw ...................................................................................................... 2 18 .................... 812345 ..................................... Spacer Plate ........................................................................................... 1

only for Freezer/Corrosion

19 .................... 796007 ..................................... Bracket ................................................................................................... 1 20 .................... 794611-001 .............................. Heater ..................................................................................................... 1 21 .................... 050004-042 .............................. Screw ...................................................................................................... 2 22 .................... 050008-011 .............................. Nut .......................................................................................................... 2 23 .................... 794590-001 .............................. Cable Assembly (inclusive 794611-001) ................................................. 1 792880-001 .............................. Pin Housing ....................................................................................... 1 792882 ..................................... Pin Insert ........................................................................................... 2 793090-001 .............................. Anti Backout ...................................................................................... 1 796011 ..................................... Heater Assembly (included 19-23) ......................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.6-2140

95

DC/DC COVERTER

1 3

2 12/24V 48V

4

MP-2140-081 MP-4.8-2140

96M1.0-0000-00096

MP-ESR4500-GB 06/04 • Printed in Germany

DC/DC COVERTER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ........................................................................ Bracket Parts (see Section 4.10) ............................................................ 1 2 ..................... 814292-001 .............................. DC/DC Converter (48 - 12V) .................................................................. 1 814292-002 .............................. DC/DC Converter (48 - 24V) .................................................................. 1 3 ..................... 050005-004 .............................. Screw ...................................................................................................... 4 4 ..................... 813753 ..................................... Loom (without Option Loom) ................................................................... 1 814056 ..................................... Loom (with Option Loom) ........................................................................ 1

Not illustrated 814338-001 .............................. Cable ....................................................................................................... 1 811995-001 .............................. Relay ....................................................................................................... 2

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.8-2140

01 REV. 05/05

97

DASH PANEL

27

26

22

23

28

24 25

21

22 23

2 1

6 5

4 7

8

3

19

20 16

12 9 10

17 15

11

18 14

13 MP-2140-039 MP-4.9-2140

98M1.0-0000-00098

MP-ESR4500-GB 06/04 • Printed in Germany

DASH PANEL INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 813271 ..................................... Dash Panel Assembly (without 19 & 20 & Freezer/Corrosion) ............... 1 1 ........................... 806898 ..................................... Dash Panel ........................................................................................ 1 2 ........................... 807349 ..................................... Brake Switch ..................................................................................... 1 3 ........................... 807034 ..................................... Key Switch Assembly (included 4) .................................................... 1 123537 ...................................... Key Switch ................................................................................... 1 793090-002 ............................... Anti-Backout ................................................................................ 1 792880-002 ............................... Pin Housing ................................................................................. 1 792882 ...................................... Pin Crimp ..................................................................................... 3 4 ........................... 107739 ..................................... Key Assembly ................................................................................... 1 107151-002 ............................... Key .............................................................................................. 2 107763 ...................................... Ring ............................................................................................. 1 5 ........................... 109127-003 .............................. Clip Arrow Indicator (red) .................................................................. 1 6 ........................... 109127-001 .............................. Clip Arrow Indicator (green) .............................................................. 1 7 ........................... 109127-002 .............................. Clip Arrow Indicator (yellow) ............................................................. 1 8 ........................... 813272 ..................................... Bracket .............................................................................................. 1 9 ........................... 803469-022 .............................. Screw ................................................................................................ 5 050009-007 .............................. Washer .............................................................................................. 5 10 .......................... 792940 ..................................... Lug Nut .............................................................................................. 2 11 .......................... 793288 ..................................... Attachment Clip ................................................................................. 2 12 .......................... 050003-015 .............................. Screw ................................................................................................ 2 13 .......................... 791346-003 .............................. Adjuster Button .................................................................................. 1 14 .......................... 790199-039 .............................. Spring ................................................................................................ 1 15 .......................... 806932 ..................................... Pivot Pin ............................................................................................ 1 16 .......................... 790213 ..................................... R-Clip ................................................................................................ 2 17 .......................... 808876 ..................................... Finger Guard ..................................................................................... 1 18 .......................... 050003-002 .............................. Screw ................................................................................................ 1 19 .................... 811036 ..................................... Shim ........................................................................................................ 4 20 .................... 050068-004 .............................. Nut .......................................................................................................... 4

only for Freezer/Corrosion 21 .................... 813058 ..................................... Bracket ................................................................................................... 1 22 .................... 794591-003 .............................. Heater Assembly .................................................................................... 1 794611-001 .............................. Heater ............................................................................................... 2 792880-001 .............................. Pin Housing ....................................................................................... 1 792882 ..................................... Pin Crimp .......................................................................................... 2 793090-001 .............................. Anti-Backout ...................................................................................... 1 23 .................... 050004-042 .............................. Screw ...................................................................................................... 4 24 .................... 050008-011 .............................. Nut .......................................................................................................... 4 25 .................... 813033 ..................................... Clamp ...................................................................................................... 1 26 .................... 813056 ..................................... Cover ...................................................................................................... 1 27 .................... 050067-014 .............................. Screw ...................................................................................................... 2 28 .................... 050008-015 .............................. Nut .......................................................................................................... 2 813060 ..................................... Key Switch Heater Assembly (included 21 - 28) ..................................... 1 796074 ..................................... Beacon Connector .................................................................................. 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.9-2140

01 REV. 05/05

99

INSTRUMENTATION

6

5 1

2

3 4

9

8

7

10

12 11

MP-2140-038 MP-4.9-2140

M1.0-0000-000100 100

MP-ESR4500-GB 06/04 • Printed in Germany

INSTRUMENTATION INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1* .................... 813077 ..................................... Display Cover ......................................................................................... 1 2* .................... 807854 ..................................... Plate ........................................................................................................ 2 3* .................... 051068-003 .............................. Clip Spring .............................................................................................. 2 4* .................... 050004-021 .............................. Screw ...................................................................................................... 4 5 ..................... 050071-035 .............................. Screw ...................................................................................................... 1 6* .................... 812269 ..................................... Display, Overlay ..................................................................................... 1 7* .................... 806748 ..................................... Button Housing ....................................................................................... 1 8* .................... 813274 ..................................... PCB Switch ............................................................................................. 1 9* .................... 813076 ..................................... PCB LCD Display ................................................................................... 4 10* ................... 803469-010 .............................. Screw ...................................................................................................... 4 11* ................... 050009-002 .............................. Washer ................................................................................................... 6 12* ................... 050005-050 .............................. Screw ...................................................................................................... 6

* ..................... 813733 ..................................... Display Assembly (included 1 - 4, 6 - 12) ............................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.9-2140

01 REV. 05/05

101

INSTRUMENTATION

6

5 1

2

3 4

9

8

7

10

12 11

MP-2140-038 MP-4.9-2140

M1.0-0000-000100 100A

MP-ESR4500-GB 06/04 • Printed in Germany

INSTRUMENTATION INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1* .................... 813077 ..................................... Display Cover ......................................................................................... 1 2* .................... 807854 ..................................... Plate ........................................................................................................ 2 3* .................... 051068-003 .............................. Clip Spring .............................................................................................. 2 4* .................... 050004-021 .............................. Screw ...................................................................................................... 4 5 ..................... 050071-035 .............................. Screw ...................................................................................................... 1 6* .................... 869560 ..................................... Display, Overlay ..................................................................................... 1 7* .................... 806748 ..................................... Button Housing ....................................................................................... 1 8* .................... 813274 ..................................... PCB Switch ............................................................................................. 1 9* .................... 816822-005 .............................. PCB LCD Display ................................................................................... 4 10* ................... 803469-010 .............................. Screw ...................................................................................................... 4 11* ................... 050009-002 .............................. Washer ................................................................................................... 6 12* ................... 050005-050 .............................. Screw ...................................................................................................... 6

* ..................... 816555-001 .............................. Display Assembly (included 1 - 4, 6 - 12) ............................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.9-2140

02 REV. 11/05

101A

FLASHING BEACON

1 1

7 6

8 10

9

8

6

2

7

9 10

3

4 5

11 4 5

20 13

18 16

17

12 15 18

19 14

MP-2140-071 MP-4.10-2140

M1.0-0000-000102 102

MP-ESR4500-GB 06/04 • Printed in Germany

FLASHING BEACON INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 791036-003 .............................. Beacon (Xenon) ...................................................................................... 1 2 ..................... 814583 ..................................... Bracket ................................................................................................... 1 3 ..................... 795982 ..................................... Bracket ................................................................................................... 1 4 ..................... 050071-020 .............................. Screw ...................................................................................................... 3 5 ..................... 050071-012 .............................. Screw ...................................................................................................... 1 6 ..................... 796045 ..................................... Clip .......................................................................................................... 1 7 ..................... 050009-007 .............................. Washer ................................................................................................... 1 8 ..................... 050008-008 .............................. Nut .......................................................................................................... 1 9 ..................... 795977 ..................................... Clamp ...................................................................................................... AR 10 .................... 050005-085 .............................. Screw ...................................................................................................... AR 11 .................... 050008-018 .............................. Nut .......................................................................................................... 4 12 .................... 818220 ..................................... Bracket ................................................................................................... 1 13 .................... 811996-001 .............................. Relay Socket .......................................................................................... 2 14 .................... 811995-001 .............................. Relay ....................................................................................................... 2 15 .................... 050071-009 .............................. Screw ...................................................................................................... 2 16 .................... 050008-008 .............................. Nut .......................................................................................................... 2 17 .................... 050071-020 .............................. Screw ...................................................................................................... 1 18 .................... 050068-002 .............................. Nut .......................................................................................................... 3 19 .................... 050067-014 .............................. Screw ...................................................................................................... 2 20 .................... 062595-002 .............................. Switch ..................................................................................................... 1

813828 ..................................... Flashing Beacon Assembly (included 1, 2, 4 - 8) .................................... 1 813827 ..................................... Flashing Beacon Assembly (included 1, 3 - 8) ........................................ 1

Not illustrated 813524 ..................................... Beacon Loom .......................................................................................... 1 813774 ..................................... Switch Loom (only for Switch Activated) ................................................ 1 793288 ..................................... Clip .......................................................................................................... 1 050003-015 .............................. Screw ...................................................................................................... 1 050008-008 .............................. Nut .......................................................................................................... 1 796495 ..................................... Pipe (Drive in Racking) ........................................................................... 1 796497 ..................................... Cable Conduit (Drive in Racking) ........................................................... 1 796707 ..................................... Cable Conduit (Drive in Racking) ........................................................... 1 050071-019 .............................. Screw (Drive in Racking) ........................................................................ 2

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.10-2140

01 REV. 11/05

103

DRIVING LIGHT

30

27

2

31 29 28 1 9 3

4 5 9

7

8 23

5

8

5 18

5

25

6 6

7 19

8

5

20 5 7 14

21 9

16

13 11

25

15 24 7 16

17 14

15

5 26

5

22 17

26

12 10

MP-2140-084 MP-4.10-2140

M1.0-0000-000104 104

MP-ESR4500-GB 06/04 • Printed in Germany

DRIVING LIGHT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 796034 ..................................... Driving Light ............................................................................................ 1 796059-006 .............................. Bulb (H4) ................................................................................................. 1 796059-007 .............................. Bulb (T4) ................................................................................................. 1 2 ..................... 796033 ..................................... Driving Light ............................................................................................ 1 796059-006 .............................. Bulb (H4) ................................................................................................. 1 796059-007 .............................. Bulb (T4) ................................................................................................. 1 3 ..................... 814437 ..................................... Bracket ................................................................................................... 1 4 ..................... 814436 ..................................... Bracket ................................................................................................... 1 5 ..................... 795977 ..................................... Clamp ...................................................................................................... AR 6 ..................... 050005-062 .............................. Screw ...................................................................................................... AR 7 ..................... 050008-014 .............................. Nut .......................................................................................................... AR 8 ..................... 050005-085 .............................. Screw ...................................................................................................... AR 9 ..................... 050008-018 .............................. Nut .......................................................................................................... AR 10 .................... 814291-001 .............................. Taillight ..................................................................................................... 1 796059-008 .............................. Bulb (P21W) ............................................................................................ 1 796059-010 .............................. Bulb (R10W) ........................................................................................... 1 11 .................... 814291-002 .............................. Taillight ..................................................................................................... 1 796059-008 .............................. Bulb (P21W) ............................................................................................ 1 796059-010 .............................. Bulb (R10W) ........................................................................................... 1 12 .................... 814404-001 .............................. Bracket ................................................................................................... 1 13 .................... 814404-002 .............................. Bracket ................................................................................................... 1 14 .................... 813484 ..................................... Plate ........................................................................................................ 2 15 .................... 793288 ..................................... Clip .......................................................................................................... 2 16 .................... 050003-014 .............................. Screw ...................................................................................................... 2 17 .................... 050008-008 .............................. Nut .......................................................................................................... 2 18 .................... 814288 ..................................... Spotlight .................................................................................................. 2 796059-011 .............................. Bulb ......................................................................................................... 2 19 .................... 050009-020 .............................. Washer ................................................................................................... 2 20 .................... 814302 ..................................... Bracket ................................................................................................... 2 21 .................... 050008-021 .............................. Nut .......................................................................................................... 2 22 .................... 796086 ..................................... Cable Conduit ......................................................................................... 1 23 .................... 814792 ..................................... Cable Conduit ......................................................................................... 1 24 .................... 814793 ..................................... Cable Conduit ......................................................................................... 1 25 .................... 796094 ..................................... Cable Conduit ......................................................................................... 1 26 .................... 050005-016 .............................. Screw ...................................................................................................... 8 27 .................... 811995-001 .............................. Relay (24V) ............................................................................................. 1 28 .................... 811995-002 .............................. Relay (12V) ............................................................................................. 1 29 .................... 050004-042 .............................. Screw ...................................................................................................... 2 30 .................... 050008-011 .............................. Nut .......................................................................................................... 2 31 .................... 062595-002 .............................. Switch ..................................................................................................... 1

814435 ..................................... Driving Light Assembly (included 1 - 4) .................................................. 1 814345-001 .............................. Taillight Assembly (included 10, 12, 15 - 17) ........................................... 1 814345-002 .............................. Taillight Assembly (included 11, 13, 15 - 17) ........................................... 1 814344 ..................................... Spotlight Assembly (included 18 - 21) ..................................................... 2

Not illustrated 813836 ..................................... Loom ....................................................................................................... 1 814336 ..................................... Loom - Adapter ....................................................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.10-2140

01 REV. 05/05

105

WORKING LIGHT 15

16

13

5 14

5

10 6

2

3

4 1 6

3

8 7

2

4

7 4 6

9

7

3

2

2 8

8

4

3

6

7 9 4

8

2 6

11

3 5 12

MP-2140-075 MP-4.10-2140

M1.0-0000-000106 106

MP-ESR4500-GB 06/04 • Printed in Germany

WORKING LIGHT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 814495 ..................................... Bracket ................................................................................................... 1 2 ..................... 795977 ..................................... Clamp ...................................................................................................... AR 3 ..................... 050005-085 .............................. Screw ...................................................................................................... AR 4 ..................... 050008-018 .............................. Nut .......................................................................................................... AR 5 ..................... 814289 ..................................... Working Light (24V) ................................................................................ AR 796059-005 .............................. Bulb (24V) ............................................................................................... AR 6 ..................... 050009-020 .............................. Washer ................................................................................................... AR 7 ..................... 050008-021 .............................. Nut .......................................................................................................... AR 8 ..................... 814302 ..................................... Bracket ................................................................................................... AR 9 ..................... 814288 ..................................... Working Light (12V) ................................................................................ AR 796059-011 .............................. Bulb (12V) ............................................................................................... AR 10 .................... 796084 ..................................... Cable Conduit ......................................................................................... 1 11 .................... 796086 ..................................... Cable Conduit ......................................................................................... 1 12 .................... 796085 ..................................... Cable Conduit ......................................................................................... 1 13 .................... 811995-001 .............................. Relay (24V) ............................................................................................. 2 811995-002 .............................. Relay (12V) ............................................................................................. 1 806703-001 .............................. Fuse (15A) .............................................................................................. 1 14 .................... 050004-034 .............................. Screw ...................................................................................................... 2 15 .................... 050008-004 .............................. Nut .......................................................................................................... 2 16 .................... 062595-002 .............................. Switch ..................................................................................................... 1

814326 ..................................... Working Light Assembly (12V/included 1, 6, 7, 9) .................................. AR 814496 ..................................... Working Light Assembly (24V/included 1, 5, 6, 7) .................................. AR 814344 ..................................... Working Light Assembly (12V/included 6, 7, 8, 9) .................................. AR 814497 ..................................... Working Light Assembly (24V/included 5, 6, 7, 8) .................................. AR

Not illustrated 813526 ..................................... Working Light Loom (12V) ...................................................................... 1 813779 ..................................... Working Light Loom (24V) ...................................................................... 1 051051-009 .............................. Cable Tie ................................................................................................. 1 793801-001 .............................. Sleeve ..................................................................................................... 1 796495 ..................................... Pipe (Drive in Racking) ........................................................................... 1 796497 ..................................... Cable Conduit (Drive in Racking) ........................................................... 1 796707 ..................................... Cable Conduit (Drive in Racking) ........................................................... 1 050071-019 .............................. Screw (Drive in Racking) ........................................................................ 2

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.10-2140

107

REVERSE ALARM

12

13

Steering Column

11 6

4

3

5 1 11

10

8 9

3 2

7

MP-2140-072 MP-4.10-2140

M1.0-0000-000108 108

MP-ESR4500-GB 06/04 • Printed in Germany

REVERSE ALARM INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1* .................... 813395 ..................................... Bracket ................................................................................................... 1 2 ..................... 050067-012 .............................. Screw ...................................................................................................... 2 3* .................... 050068-002 .............................. Nut .......................................................................................................... 4 4* .................... 126035 ..................................... Reverse Alarm ........................................................................................ 1 5* .................... 050009-012 .............................. Washer ................................................................................................... 2 6* .................... 050006-024 .............................. Screw ...................................................................................................... 2 7* .................... 796401 ..................................... Cable ....................................................................................................... 1 8 ..................... 811996-001 .............................. Relay Socket .......................................................................................... 2 9 ..................... 050071-009 .............................. Screw ...................................................................................................... 2 10 .................... 811995-001 .............................. Relay ....................................................................................................... 2 11 .................... 050008-008 .............................. Nut .......................................................................................................... 3 12 .................... 793288 ..................................... Clip .......................................................................................................... 1 13 .................... 050003-014 .............................. Screw ...................................................................................................... 1

* ..................... 813394 ..................................... Reverse Alarm Assembly (included 1, 3 - 7) .......................................... 1

Not illustrated 813527 ..................................... Reverse Alarm Loom .............................................................................. 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.10-2140

01 REV. 05/05

109

BRACKET PARTS

1

2

7 8 5

6

2 3

4

2 2

3 3

9

4

4

MP-2140-073 MP-4.10-2140

M1.0-0000-000110 110

MP-ESR4500-GB 06/04 • Printed in Germany

BRACKET PARTS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1* .................... 813353 ..................................... Bracket ................................................................................................... 1 2* .................... 050078-007 .............................. Blind Rivet Nut ........................................................................................ 21 3* .................... 793288 ..................................... Clip .......................................................................................................... 8 4* .................... 050003-012 .............................. Screw ...................................................................................................... 8 5 ..................... 813445 ..................................... Loom ....................................................................................................... 1 6 ..................... 050071-009 .............................. Screw ...................................................................................................... 6 7 ..................... 050070-002 .............................. Screw ...................................................................................................... 3 8 ..................... 813710 ..................................... Sleeve ..................................................................................................... 2 9 ..................... 050068-004 .............................. Nut .......................................................................................................... 2

* ..................... 813453 ..................................... Bracket Assembly (included 1 - 4) .......................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.10-2140

111

HORN

2

1

3

MP-2140-041 MP-4.13-2140

M1.0-0000-000112 112

MP-ESR4500-GB 06/04 • Printed in Germany

HORN INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 129574 ..................................... Horn ........................................................................................................ 1 2 ..................... 050006-032 .............................. Screw ...................................................................................................... 1 3 ..................... 050008-024 .............................. Nut .......................................................................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.13-2140

113

COOLING SYSTEM 2

7 3

10 9 5

6

7

4

13 6 13

5

12

1 8 9

11

MP-2140-037 MP-4.14-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05 M1.0-0000-000114 114

COOLING SYSTEM INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 807620 ..................................... Bracket ................................................................................................... 1 2 ..................... 793288 ..................................... Clip .......................................................................................................... 2 3 ..................... 050003-013 .............................. Screw ...................................................................................................... 2 4 ..................... 050008-008 .............................. Nut .......................................................................................................... 2 5 ..................... 806895-002 .............................. Fan Assembly ......................................................................................... 2 807654-001 .............................. Fan .................................................................................................... 2 792880-001 .............................. Pin Housing ....................................................................................... 2 792882 ..................................... Pin Insert ........................................................................................... 4 793090-001 .............................. Anti-backout ...................................................................................... 2 6 ..................... 807797 ..................................... Finger Guard ........................................................................................... 2 7 ..................... 050005-003 .............................. Screw ...................................................................................................... 8 8 ..................... 050008-005 .............................. Nut .......................................................................................................... 2 9 ..................... 050009-018 .............................. Washer ................................................................................................... 4 10 .................... 050008-024 .............................. Nut .......................................................................................................... 2 11 .................... 807849 ..................................... Bracket ................................................................................................... 1 12 .................... 050006-022 .............................. Screw ...................................................................................................... 2 13 .................... 050078-006 .............................. Blind Rivet Nut ........................................................................................ 8

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-4.14-2140

02 REV. 11/05

115

Page intentionally left blank

Printed in Germany

M1.0-0000-000116 116

SECTION 5

Printed in Germany

117

BRAKE CIRCUIT

1 4 5 3 22

6 1 2

17 4 6

5

10

10 9

7

A

9

13 8 20 14

12 19 11 18 19

21

17

16

A MP-2140-048 MP-5.1-2140

M1.0-0000-000118 118

MP-ESR4500-GB 05/05 • Printed in Germany

BRAKE CIRCUIT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ........................................................................ Load Wheel Brake (see Section 5.6) ....................................................... 2 2 ..................... 810580-001 .............................. Brake Line (1.4t/1285mm Leg Width) ...................................................... 1 810580-002 .............................. Brake Line (1.6-2.0t/1285mm Leg Width) ................................................ 1 810580-003 .............................. Brake Line (1.4t/1425mm Leg Width) ...................................................... 1 810580-004 .............................. Brake Line (1.6-2.0t/1425mm Leg Width) ................................................ 1 810580-005 .............................. Brake Line (1.4t/1575mm Leg Width) ...................................................... 1 810580-006 .............................. Brake Line (1.6-2.0t/1575mm Leg Width) ................................................ 1 3 ..................... 810581-001 .............................. Brake Line (1.4t/1285mm Leg Width) ...................................................... 1 810581-002 .............................. Brake Line (1.6-2.0t/1285mm Leg Width) ................................................ 1 810581-003 .............................. Brake Line (1.4t/1425mm Leg Width) ...................................................... 1 810581-004 .............................. Brake Line (1.6-2.0t/1425mm Leg Width) ................................................ 1 810581-005 .............................. Brake Line (1.4t/1575mm Leg Width) ...................................................... 1 810581-006 .............................. Brake Line (1.6-2.0t/1575mm Leg Width) ................................................ 1 4 ..................... 790555 ..................................... Clip .......................................................................................................... 2 5 ..................... 050006-008 .............................. Screw ...................................................................................................... 2 6 ..................... 790548 ..................................... Connector ............................................................................................... AR 7 ..................... 807553-001 .............................. Brake Line (1285/1425mm Leg Width) .................................................... 1 807553-002 .............................. Brake Line (1575mm Leg Width) ............................................................. 1 8 ..................... 807585 ..................................... Clip .......................................................................................................... 1 9 ..................... 050008-030 .............................. Nut .......................................................................................................... 3 10 .................... 050070-002 .............................. Screw ...................................................................................................... 3 11 .................... 790550 ..................................... Connector ............................................................................................... 1 12 .................... 050007-009 .............................. Screw ...................................................................................................... 1 13 .................... 807499 ..................................... Bracket ................................................................................................... 1 14 .................... 050006-036 .............................. Screw ...................................................................................................... 1 15 .................... 813003 ..................................... Brake Line ............................................................................................... 1 16 ....................................................................... Brake Master Cylinder (see Section 5.5) ................................................ 1 17 .................... 812163 ..................................... Brake Line ............................................................................................... 1 18 .................... 054193-001 .............................. Banjo Fitting ............................................................................................ 1 19 .................... 050011-015 .............................. Washer ................................................................................................... 2 20 .................... 054192-001 .............................. Screw ...................................................................................................... 1 21 ....................................................................... Drive Motor Brake (see Section 5.6) ....................................................... 1 22 .................... 807703 ..................................... Brake Line (only for 1575mm Leg Width) ................................................ 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 05/05 • Printed in Germany

MP-5.1-2140

119

FOOTBRAKE 19 5 17 16 18 2

10 4 11

12 14

15

13

9

1

6

7 8

3

Drive Frame

MP-2140-034 MP-5.5-2140

M1.0-0000-000120 120

MP-ESR4500-GB 05/05 • Printed in Germany

FOOTBRAKE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 813245-001 .............................. Footbrake Assembly ............................................................................... 1 1* .......................... 810399 ..................................... Brake Mounting Bracket .................................................................... 1 2 ........................... 050067-047 .............................. Screw ................................................................................................ 2 3 ........................... 812345 ..................................... Spacer Plate ...................................................................................... 1 4* .......................... 810401 ..................................... Brake Pedal ....................................................................................... 1 5* .......................... 102330 ..................................... Footpedal Rubber .............................................................................. 1 6* .......................... 055084-009 .............................. Bush .................................................................................................. 2 7* .......................... 050009-053 .............................. Washer .............................................................................................. 1 8* .......................... 050012-036 .............................. Circlip ................................................................................................ 1 9* .......................... 050007-013 .............................. Screw ................................................................................................ 1 10* ......................... 807085 ..................................... Spring ................................................................................................ 1 11* ......................... 050008-015 .............................. Nut ..................................................................................................... 2 12* ......................... 810404 ..................................... Rod Fork ........................................................................................... 1 13* ......................... 790195 ..................................... Pin Clevis .......................................................................................... 1 14* ......................... 050001-013 .............................. Pin ..................................................................................................... 1 15* ......................... 050009-018 .............................. Washer .............................................................................................. 1 16* ......................... 810525 ..................................... Brake Master Cylinder Assembly ...................................................... 1 810589 ...................................... Brake Master Cylinder & Reservoir ............................................. 1 810591 ...................................... Reservoir Cap & Switch (BFS) .................................................... 1 17* ......................... 812293 ..................................... Brake Switch ..................................................................................... 1 18* ......................... 050006-035 .............................. Screw ................................................................................................ 1 19* ......................... 050006-043 .............................. Screw ................................................................................................ 1

* ........................... 813244-001 .............................. Footbrake Assembly (inkluded 1,4-19) .............................................. 1

810700 ..................................... Repair Kit (Brake Master Cylinder) ................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 05/05 • Printed in Germany

MP-5.5-2140

121

DRIVE MOTOR BRAKE

1

3

2

4

5

6

MP-2140-076 MP-5.6-2140

M1.0-0000-000122 122

MP-ESR4500-GB 05/05 • Printed in Germany

DRIVE MOTOR BRAKE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 811000 ..................................... Drive Motor Brake Assembly .................................................................. 1 1 ........................... 050005-97 ................................ Screw ................................................................................................ 3 2 ........................... 813259 ..................................... Drive Motor Brake ............................................................................. 1 3 ........................... 792881-002 .............................. Socket Housing ................................................................................. 1 792883 ..................................... Socket Crimp .................................................................................... 2 793091-002 .............................. Anti Backout ...................................................................................... 1 4 ........................... 813041 ..................................... Hub .................................................................................................... 1 5 ........................... 813040 ..................................... Brake Rotor Disc .............................................................................. 1 6 ........................... 813042 ..................................... Brake Disk ........................................................................................ 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 05/05 • Printed in Germany

MP-5.6-2140

123

LOAD WHEEL BRAKE

2 1 4

5

2

3 6

5 6

7

8

MP-2140-033 MP-5.6-2140

M1.0-0000-000124 124

MP-ESR4500-GB 05/05 • Printed in Germany

LOAD WHEEL BRAKE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 810564 ..................................... Brake ...................................................................................................... 2 1 ........................... 810569 ..................................... Backplate .......................................................................................... 2 2 ........................... 810634 ..................................... Plug ................................................................................................... 4 3 ........................... 810572 ..................................... Cylinder Assy .................................................................................... 2 4 ........................... 050006-024 .............................. Screw ................................................................................................ 4 5 ........................... 810570 ..................................... Brake Shoe ....................................................................................... 4 6 ........................... 810568 ..................................... Spring ................................................................................................ 4 7 ........................... 810567 ..................................... Spring ................................................................................................ 4 8 ........................... 810566 ..................................... Clamp ................................................................................................ 2

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 05/05 • Printed in Germany

MP-5.6-2140

125

Page intentionally left blank

Printed in Germany

M1.0-0000-000126 126

SECTION 6

Printed in Germany

127

STEER MOTOR

1

2

3

4

MP-2140-078 MP-6.2-2140

M1.0-0000-000128 128

MP-ESR4500-GB 06/04 • Printed in Germany

STEER MOTOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 812992 ..................................... Steer Motor Assembly ............................................................................ 1 1 ........................... 812995 ..................................... Steer Motor ........................................................................................ 1 2 ........................... 813039 ..................................... Coupling ............................................................................................ 1 3 ........................... 812994 ..................................... Speed Reducer ................................................................................. 1 4 ........................... 050005-099 .............................. Screw ................................................................................................ 8

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-6.2-2140

129

STEER MOTOR

1

2

3

4

MP-2140-078 MP-6.2-2140

M1.0-0000-000128 128A

MP-ESR4500-GB 06/04 • Printed in Germany

STEER MOTOR INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 818448 ..................................... Steer Motor Assembly ............................................................................ 1 1 ........................... 816263 ..................................... Steer Motor ........................................................................................ 1 2 ........................... 813039 ..................................... Coupling ............................................................................................ 1 3 ........................... 818449 ..................................... Speed Reducer ................................................................................. 1 4 ........................... 050005-099 .............................. Screw ................................................................................................ 8

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-6.2-2140

01 REV. 11/05

129A

STEERING COLUMN

17

18 19

20

15 3 14

4 12

2

13 31 30 32

1

10

11

2

9

29 5 28

16 8 7

22

6

21 24 28

23 25

26

27

MP-2140-031 MP-6.7-2140

M1.0-0000-000130 130

MP-ESR4500-GB 06/04 • Printed in Germany

STEERING COLUMN INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1* .................... 813692 ..................................... Steering Column ..................................................................................... 1 2* .................... 050078-002 .............................. Blind Rivet Nut ........................................................................................ 5 3* .................... 050003-013 .............................. Screw ...................................................................................................... 1 4* .................... 793288 ..................................... Clip .......................................................................................................... 1 5* .................... 050008-008 .............................. Nut .......................................................................................................... 1 6* .................... 050003-059 .............................. Screw ...................................................................................................... 2 7* .................... 050010-023 .............................. Washer ................................................................................................... 2 8* .................... 794301 ..................................... Lock Plate ............................................................................................... 1 9* .................... 807408 ..................................... Spacer Block .......................................................................................... 1 10* ................... 807410 ..................................... Spacer Plate ........................................................................................... 2 11* ................... 050008-024 .............................. Nut .......................................................................................................... 2 12* ................... 807750 ..................................... Spring Mount ........................................................................................... 1 13 .................... 050009-013 .............................. Washer ................................................................................................... 1 14 .................... 050006-022 .............................. Screw ...................................................................................................... 1 15 .................... 790995 ..................................... Spring ..................................................................................................... 2 16* ................... 050008-049 .............................. Nut .......................................................................................................... 1 17* ................... 050012-014 .............................. Circlip ...................................................................................................... 1 18* ................... 050012-009 .............................. Circlip ...................................................................................................... 1 19* ................... 055002-014 .............................. Bearing Ball ............................................................................................. 1 20* ................... 816549 ..................................... Bearing Stud ........................................................................................... 1 21* ................... 816548 ..................................... Brake Disc .............................................................................................. 1 22* ................... 050003-025 .............................. Screw ...................................................................................................... 3 23* ................... 050003-014 .............................. Screw ...................................................................................................... 4 24* ................... 811495 ..................................... Plate ........................................................................................................ 1 25* ................... 050006-023 .............................. Screw ...................................................................................................... 4 26* ................... 811229 ..................................... Motor ....................................................................................................... 1 27* ................... 050008-010 .............................. Nut .......................................................................................................... 4 28 .................... 051058-018 .............................. Bushing ................................................................................................... 2 803915-001 .............................. Shim (0,5 mm) ......................................................................................... AR 803915-002 .............................. Shim (1,0 mm) ......................................................................................... AR 803915-003 .............................. Shim (1,5 mm) ......................................................................................... AR 29 .................... 806961 ..................................... Shaft ........................................................................................................ 1 30 .................... 792973 ..................................... Pin ........................................................................................................... 1 31 .................... 050006-027 .............................. Screw ...................................................................................................... 1 32* ................... 812120 ..................................... Stud ......................................................................................................... 2

* ..................... 813700 ..................................... Steering Column Assembly (included 1-12, 16-27 & 32) ......................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-6.7-2140

01 REV. 05/05

131

Page intentionally left blank

Printed in Germany

M1.0-0000-000132 132

SECTION 7

Printed in Germany

133

TT MAST 1.4t/1.6t

9 25

5

10

4

11 18

26

13

12

17

14 19

8 16

6 23 24 20

7

3 4

9

5

7 21

2 22

10 12 14

7 11 13

31

30 29

15

1

28

27

MP-2140-055 MP-7.5-2140

M1.0-0000-000134 134

MP-ESR4500-GB 06/04 • Printed in Germany

TT MAST INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 806271-***-** ........................... Outer Mast (see next page) .................................................................... 1 813010-***-** ........................... Outer Mast (see next page) .................................................................... 1 2 ..................... 806272-*** ............................... 1st Stage Mast (see next page) .............................................................. 1 813011-*** ............................... 1st Stage Mast (see next page) .............................................................. 1 3 ..................... 806273-*** ............................... 2nd Stage Mast (see next page) ............................................................. 1 4 ..................... 060030-057 .............................. Shim ........................................................................................................ 8 060030-085 .............................. Shim ........................................................................................................ 8 795534 ..................................... Shim ........................................................................................................ 8 5 ..................... 807334-002 .............................. Roller ∅ 101,47mm ................................................................................. AR 807334-003 .............................. Roller ∅ 102,14mm ................................................................................. AR 807334-004 .............................. Roller ∅ 102,45mm ................................................................................. AR 6 ..................... 807327-*** ............................... Cover (see next page) ............................................................................ 1 812967-*** ............................... Cover (see next page) ............................................................................ 1 7 ..................... 050067-022 .............................. Screw ...................................................................................................... AR 8 ..................... 806999-*** ............................... Cover (see next page) ............................................................................ 1 812966-*** ............................... Cover (see next page) ............................................................................ 1 9 ..................... 050006-069 .............................. Screw ...................................................................................................... 8 10 .................... 792427 ..................................... Block Stop .............................................................................................. 4 11 .................... 794661 ..................................... Shim ........................................................................................................ 4 12 .................... 808861 ..................................... Bracket ................................................................................................... 4 13 .................... 092747-001 .............................. Poly Stop ................................................................................................. 4 14 .................... 050005-062 .............................. Screw ...................................................................................................... 4 15 ....................................................................... Lift Cylinder (see Section 8.1) ................................................................. 2 16 .................... 806997 ..................................... Pin ........................................................................................................... 2 050001-021 .............................. Pin Split ................................................................................................... 2 17 .................... 050067-048 .............................. Screw ...................................................................................................... 2 050008-038 .............................. Nut .......................................................................................................... 2 18 .................... 050007-014 .............................. Screw ...................................................................................................... 2 19 .................... 050008-015 .............................. Nut .......................................................................................................... 2 20 ....................................................................... Freelift Cylinder (see Section 8.2) ........................................................... 1 21 .................... 807339 ..................................... Protection ................................................................................................ 1 22 .................... 050003-050 .............................. Screw ...................................................................................................... 2 23 .................... 807329 ..................................... Shim ........................................................................................................ 1 24 .................... 050067-037 .............................. Screw ...................................................................................................... 2 25 ....................................................................... Yoke (see Section 7.11) .......................................................................... 1 26 .................... 050000-028 .............................. Pin ........................................................................................................... 1 27 .................... 050067-056 .............................. Screw ...................................................................................................... 2 28 .................... 807407 ..................................... Washer ................................................................................................... 2 29 .................... 807323 ..................................... Shim ........................................................................................................ 8 30 .................... 050068-007 .............................. Nut .......................................................................................................... 2 31 .................... 812968 ..................................... Cover (RH/only for Collapsed Height 3692,3892,3952mm) ................... 1 812969 ..................................... Cover (LH/only for Collapsed Height 3692,3892,3952mm) .................... 1

Not shown 790350 ..................................... Magnet (FLS/LCS) .................................................................................. AR 050003-019 .............................. Screw (FLS/LCS) ................................................................................... AR 807716 ..................................... Bracket (FLS/LCS) ................................................................................. AR 050005-058 .............................. Screw (FLS/LCS) ................................................................................... AR

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-7.5-2140

135

TT MAST 1.4t/1.6t Position 1

Position 2

Position 3

Position 6

Position 8

Collapsed Height

806271-001-01

806272-001

806273-001

807327-001

806999-001

2022mm

806271-001-02

806272-002

806273-002

807327-002

806999-002

2172mm

806271-001-03

806272-003

806273-003

807327-003

806999-003

2322mm

806271-001-04

806272-004

806273-004

807327-004

806999-004

2472mm

806271-001-05

806272-005

806273-005

807327-005

806999-005

2572mm

806271-001-06

806272-006

806273-006

807327-006

806999-006

2772mm

806271-001-07

806272-007

806273-007

807327-007

806999-007

2922mm

806271-001-08

806272-008

806273-008

807327-008

806999-008

3042mm

806271-001-09

806272-009

806273-009

807327-009

806999-009

3192mm

813010-001-10

813011-010

806273-010

807327-010

806999-010

3347mm

813010-001-11

813011-011

806273-011

807327-011

806999-011

3492mm

813010-001-12

813011-012

806273-012

812967-012

812966-012

3692mm

813010-001-13

813011-013

806273-013

812967-013

812966-013

3842mm

813010-001-14

813011-014

806273-014

812967-014

812966-014

3952mm Tab010gb

MP-7.5-2140

M1.0-0000-000136 136

MP-ESR4500-GB 06/04 • Printed in Germany

Page intentionally left blank

Printed in Germany

137

TT MAST 1.4t/1.6t

9 25

5

10

4

11 18

26

13

12

17

14 19

8 16

6 23 24 20

7

3 4

9

5

7 21

2 22

10 12 14

7 11 13

31

29 28 1

15

Reach Carriage

30

27

MP-2140-109 MP-7.5-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05 M1.0-0000-000134 134A

TT MAST INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 815491-***-** ........................... Outer Mast (see next page) .................................................................... 1 815492-***-** ........................... Outer Mast (see next page) .................................................................... 1 2 ..................... 815493-*** ............................... 1st Stage Mast (see next page) .............................................................. 1 815494-*** ............................... 1st Stage Mast (see next page) .............................................................. 1 3 ..................... 806103-*** ............................... 2nd Stage Mast (see next page) ............................................................. 1 4 ..................... 060030-057 .............................. Shim ........................................................................................................ 8 060030-085 .............................. Shim ........................................................................................................ 8 795534 ..................................... Shim ........................................................................................................ 8 5 ..................... 813806-002 .............................. Roller ∅ 101,30 mm ................................................................................ AR 813806-003 .............................. Roller ∅ 101,72 mm ................................................................................ AR 813806-004 .............................. Roller ∅ 102,14 mm ................................................................................ AR 6 ..................... 807327-*** ............................... Cover (see next page) ............................................................................ 1 812967-*** ............................... Cover (see next page) ............................................................................ 1 7 ..................... 050067-022 .............................. Screw ...................................................................................................... AR 8 ..................... 806999-*** ............................... Cover (see next page) ............................................................................ 1 812966-*** ............................... Cover (see next page) ............................................................................ 1 9 ..................... 050006-069 .............................. Screw ...................................................................................................... 8 10 .................... 792427 ..................................... Block Stop .............................................................................................. 4 11 .................... 794661 ..................................... Shim ........................................................................................................ 4 12 .................... 808861 ..................................... Bracket ................................................................................................... 4 13 .................... 092747-001 .............................. Poly Stop ................................................................................................. 4 14 .................... 050005-062 .............................. Screw ...................................................................................................... 4 15 ....................................................................... Lift Cylinder (see Section 8.1) ................................................................. 2 16 .................... 806997 ..................................... Pin ........................................................................................................... 2 050001-021 .............................. Pin Split ................................................................................................... 2 17 .................... 050067-048 .............................. Screw ...................................................................................................... 2 050008-038 .............................. Nut .......................................................................................................... 2 18 .................... 050007-014 .............................. Screw ...................................................................................................... 2 19 .................... 050008-015 .............................. Nut .......................................................................................................... 2 20 ....................................................................... Freelift Cylinder (see Section 8.2) ........................................................... 1 21 .................... 807339 ..................................... Protection ................................................................................................ 1 22 .................... 050003-050 .............................. Screw ...................................................................................................... 2 23 .................... 807329 ..................................... Shim ........................................................................................................ 1 24 .................... 050067-037 .............................. Screw ...................................................................................................... 2 25 ....................................................................... Yoke (see Section 7.11) .......................................................................... 1 26 .................... 050000-028 .............................. Pin ........................................................................................................... 1 27 .................... 050067-059 .............................. Screw (Load Wheel 285 mm) .................................................................. 2 050067-056 .............................. Screw (Load Wheel 330 mm) .................................................................. 2 28 .................... 807407 ..................................... Washer ................................................................................................... 2 29 .................... 807323 ..................................... Shim ........................................................................................................ 8 30 .................... 050068-007 .............................. Nut .......................................................................................................... 2 31 .................... 812968 ..................................... Cover (RH/only for Collapsed Height 3692,3892,3952mm) ................... 1 812969 ..................................... Cover (LH/only for Collapsed Height 3692,3892,3952mm) .................... 1

Not shown 790350 ..................................... Magnet (FLS/LCS) .................................................................................. AR 050003-019 .............................. Screw (FLS/LCS) ................................................................................... AR 050009-008 .............................. Washer (FLS/LCS) ................................................................................. AR 050008-001 .............................. Nut (FLS/LCS) ........................................................................................ AR 807716 ..................................... Bracket (FLS/LCS) ................................................................................. AR 050005-058 .............................. Screw (FLS/LCS) ................................................................................... AR

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-7.5-2140

01 REV. 05/05

135A

TT MAST 1.4t/1.6t Position 1

Position 2

Position 3

Position 6

Position 8

Collapsed Height

815491-001-01

815493-001

806103-001

807327-001

806999-001

2022mm

815491-001-02

815493-002

806103-002

807327-002

806999-002

2172mm

815491-001-03

815493-003

806103-003

807327-003

806999-003

2322mm

815491-001-04

815493-004

806103-004

807327-004

806999-004

2472mm

815491-001-05

815493-005

806103-005

807327-005

806999-005

2572mm

815491-001-06

815493-006

806103-006

807327-006

806999-006

2772mm

815491-001-07

815493-007

806103-007

807327-007

806999-007

2922mm

815491-001-08

815493-008

806103-008

807327-008

806999-008

3042mm

815491-001-09

815493-009

806103-009

807327-009

806999-009

3192mm

815492-001-10

815494-010

806103-010

807327-010

806999-010

3347mm

815492-001-11

815494-011

806103-011

807327-011

806999-011

3492mm

815492-001-12

815494-012

806103-012

812967-012

812966-012

3692mm

815492-001-13

815494-013

806103-013

812967-013

812966-013

3842mm

815492-001-14

815494-014

806103-014

812967-014

812966-014

3952mm Tab021gb

MP-7.5-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05 M1.0-0000-000136 136A

Page intentionally left blank

Printed in Germany

137

TT MAST 2.0t

9 25

5

10

4

11 18

26

13

12

17

14 19

8 16

6 23 24 20

7

3 4

9

5 21

2 22

10 12 14

7 11 13

30 29

15

1

28

27

MP-2140-056 MP-7.5-2140

M1.0-0000-000138 138

MP-ESR4500-GB 06/04 • Printed in Germany

TT MAST INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 806271-***-** ........................... Outer Mast (see next page) .................................................................... 1 813010-***-** ........................... Outer Mast (see next page) .................................................................... 1 2 ..................... 806272-*** ............................... 1st Stage Mast (see next page) .............................................................. 1 813011-*** ............................... 1st Stage Mast (see next page) .............................................................. 1 3 ..................... 806273-*** ............................... 2nd Stage Mast (see next page) ............................................................. 1 4 ..................... 060030-057 .............................. Shim ........................................................................................................ 8 060030-085 .............................. Shim ........................................................................................................ 8 795534 ..................................... Shim ........................................................................................................ 8 5 ..................... 807334-002 .............................. Roller ∅ 101,47mm ................................................................................. AR 807334-003 .............................. Roller ∅ 102,14mm ................................................................................. AR 807334-004 .............................. Roller ∅ 102,45mm ................................................................................. AR 6 ..................... 807327-*** ............................... Cover (see next page) ............................................................................ 1 812973-***-01 .......................... Cover (see next page) ............................................................................ 1 7 ..................... 050067-022 .............................. Screw ...................................................................................................... AR 8 ..................... 806999-*** ............................... Cover (see next page) ............................................................................ 1 812973-***-02 .......................... Cover (see next page) ............................................................................ 1 9 ..................... 050006-069 .............................. Screw ...................................................................................................... 8 10 .................... 792427 ..................................... Block Stop .............................................................................................. 4 11 .................... 794661 ..................................... Shim ........................................................................................................ 4 12 .................... 808861 ..................................... Bracket ................................................................................................... 4 13 .................... 092747-001 .............................. Poly Stop ................................................................................................. 4 14 .................... 050005-062 .............................. Screw ...................................................................................................... 4 15 ....................................................................... Lift Cylinder (see Section 8.1) ................................................................. 2 16 .................... 806997 ..................................... Pin ........................................................................................................... 2 050001-021 .............................. Pin Split ................................................................................................... 2 17 .................... 050067-048 .............................. Screw ...................................................................................................... 2 050008-038 .............................. Nut .......................................................................................................... 2 18 .................... 050007-014 .............................. Screw ...................................................................................................... 2 19 .................... 050008-015 .............................. Nut .......................................................................................................... 2 20 ....................................................................... Freelift Cylinder (see Section 8.2) ........................................................... 1 21 .................... 807339 ..................................... Protection ................................................................................................ 1 22 .................... 050003-050 .............................. Screw ...................................................................................................... 2 23 .................... 807329 ..................................... Shim ........................................................................................................ 1 24 .................... 050067-037 .............................. Screw ...................................................................................................... 2 25 ....................................................................... Yoke (see Section 7.11) .......................................................................... 1 26 .................... 050000-028 .............................. Pin ........................................................................................................... 1 27 .................... 050067-056 .............................. Screw ...................................................................................................... 2 28 .................... 807407 ..................................... Washer ................................................................................................... 2 29 .................... 807323 ..................................... Shim ........................................................................................................ 8 30 .................... 050068-007 .............................. Nut .......................................................................................................... 2

Not shown 790350 ..................................... Magnet (FLS/LCS) .................................................................................. AR 050003-019 .............................. Screw (FLS/LCS) ................................................................................... AR 807716 ..................................... Bracket (FLS/LCS) ................................................................................. AR 050005-058 .............................. Screw (FLS/LCS) ................................................................................... AR

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-7.5-2140

139

TT MAST 2.0t Position 1

Position 2

Position 3

Position 6

Position 8

Collapsed Height

806271-002-01

806272-001

806273-001

807327-001

806999-001

2022mm

806271-002-02

806272-002

806273-002

807327-002

806999-002

2172mm

806271-002-04

806272-004

806273-004

807327-004

806999-004

2472mm

806271-002-06

806272-006

806273-006

807327-006

806999-006

2772mm

806271-002-07

806272-007

806273-007

807327-007

806999-007

2922mm

806271-002-08

806272-008

806273-008

807327-008

806999-008

3042mm

813010-002-10

813011-010

806273-010

812973-010-01

812973-010-02

3347mm

813010-002-12

813011-012

806273-012

812973-012-01

812973-012-02

3692mm

813010-002-13

813011-013

806273-013

812973-013-01

812973-013-02

3842mm

813010-002-14

813011-014

806273-014

812973-014-01

812973-014-02

3952mm

813010-002-15

813011-015

806273-015

812973-015-01

812973-015-02

4252mm

813010-002-16

813011-016

806273-016

812973-016-01

812973-016-02

4452mm Tab011gb

MP-7.5-2140

M1.0-0000-000140 140

MP-ESR4500-GB 06/04 • Printed in Germany

Page intentionally left blank

Printed in Germany

141

TT MAST 2.0t

9 25

5

10

4

11 18

26

13

12

17

14 19

8 16

6 23 24 20

7

3 4

9

5 21

2 22

10 12 14

7 11 13

29 28 1

15

Reach Carriage

30

27 MP-2140-110

MP-7.5-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05 M1.0-0000-000138 138A

TT MAST INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 815491-***-** ........................... Outer Mast (see next page) .................................................................... 1 815492-***-** ........................... Outer Mast (see next page) .................................................................... 1 2 ..................... 815493-*** ............................... 1st Stage Mast (see next page) .............................................................. 1 815494-*** ............................... 1st Stage Mast (see next page) .............................................................. 1 3 ..................... 806103-*** ............................... 2nd Stage Mast (see next page) ............................................................. 1 4 ..................... 060030-057 .............................. Shim ........................................................................................................ 8 060030-085 .............................. Shim ........................................................................................................ 8 795534 ..................................... Shim ........................................................................................................ 8 5 ..................... 813806-002 .............................. Roller ∅ 101,30 mm ................................................................................ AR 813806-003 .............................. Roller ∅ 101,72 mm ................................................................................ AR 813806-004 .............................. Roller ∅ 102,14 mm ................................................................................ AR 6 ..................... 807327-*** ............................... Cover (see next page) ............................................................................ 1 812973-***-01 .......................... Cover (see next page) ............................................................................ 1 7 ..................... 050067-022 .............................. Screw ...................................................................................................... AR 8 ..................... 806999-*** ............................... Cover (see next page) ............................................................................ 1 812973-***-02 .......................... Cover (see next page) ............................................................................ 1 9 ..................... 050006-069 .............................. Screw ...................................................................................................... 8 10 .................... 792427 ..................................... Block Stop .............................................................................................. 4 11 .................... 794661 ..................................... Shim ........................................................................................................ 4 12 .................... 808861 ..................................... Bracket ................................................................................................... 4 13 .................... 092747-001 .............................. Poly Stop ................................................................................................. 4 14 .................... 050005-062 .............................. Screw ...................................................................................................... 4 15 ....................................................................... Lift Cylinder (see Section 8.1) ................................................................. 2 16 .................... 806997 ..................................... Pin ........................................................................................................... 2 050001-021 .............................. Pin Split ................................................................................................... 2 17 .................... 050067-048 .............................. Screw ...................................................................................................... 2 050008-038 .............................. Nut .......................................................................................................... 2 18 .................... 050007-014 .............................. Screw ...................................................................................................... 2 19 .................... 050008-015 .............................. Nut .......................................................................................................... 2 20 ....................................................................... Freelift Cylinder (see Section 8.2) ........................................................... 1 21 .................... 807339 ..................................... Protection ................................................................................................ 1 22 .................... 050003-050 .............................. Screw ...................................................................................................... 2 23 .................... 807329 ..................................... Shim ........................................................................................................ 1 24 .................... 050067-037 .............................. Screw ...................................................................................................... 2 25 ....................................................................... Yoke (see Section 7.11) .......................................................................... 1 26 .................... 050000-028 .............................. Pin ........................................................................................................... 1 27 .................... 050067-059 .............................. Screw (Load Wheel 285 mm) .................................................................. 2 050067-056 .............................. Screw (Load Wheel 330 mm) .................................................................. 2 28 .................... 807407 ..................................... Washer ................................................................................................... 2 29 .................... 807323 ..................................... Shim ........................................................................................................ 8 30 .................... 050068-007 .............................. Nut .......................................................................................................... 2

Not shown 790350 ..................................... Magnet (FLS/LCS) .................................................................................. AR 050003-019 .............................. Screw (FLS/LCS) ................................................................................... AR 050009-008 .............................. Washer (FLS/LCS) ................................................................................. AR 050008-001 .............................. Nut (FLS/LCS) ........................................................................................ AR 807716 ..................................... Bracket (FLS/LCS) ................................................................................. AR 050005-058 .............................. Screw (FLS/LCS) ................................................................................... AR

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-7.5-2140

01 REV. 05/05

139A

TT MAST 2.0t Position 1

Position 2

Position 3

Position 6

Position 8

Collapsed Height

815491-002-01

815493-001

806103-001

807327-001

806999-001

2022mm

815491-002-02

815493-002

806103-002

807327-002

806999-002

2172mm

815491-002-04

815493-004

806103-004

807327-004

806999-004

2472mm

815491-002-06

815493-006

806103-006

807327-006

806999-006

2772mm

815491-002-07

815493-007

806103-007

807327-007

806999-007

2922mm

815491-002-08

815493-008

806103-008

807327-008

806999-008

3042mm

815492-002-10

815494-010

806103-010

812973-010-01

812973-010-02

3347mm

815492-002-12

815494-012

806103-012

812973-012-01

812973-012-02

3692mm

815492-002-13

815494-013

806103-013

812973-013-01

812973-013-02

3842mm

815492-002-14

815494-014

806103-014

812973-014-01

812973-014-02

3952mm

815492-002-15

815494-015

806103-015

812973-015-01

812973-015-02

4252mm

815492-002-16

815494-016

806103-016

812973-016-01

812973-016-02

4452mm Tab022gb

MP-7.5-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05 M1.0-0000-000140 140A

Page intentionally left blank

Printed in Germany

141

TT MAST 1.4t/1.6t & 2.0t

23 14

13

11 10

15 24 25

21

26

31 30 8

9

15 12 14

10 10

18

17

28 29 20

30 16

7 4

6 5

24

22

23 21 28 29 20

27

6

3 2 1

7 19 5

Fork Carriage

3 2 1

MP-2140-057 MP-7.6-2140

M1.0-0000-000142 142

MP-ESR4500-GB 06/04 • Printed in Germany

TT MAST INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 050008-056 .............................. Nut .......................................................................................................... 8 2 ..................... 806993 ..................................... Washer ................................................................................................... 4 3 ..................... 806995 ..................................... Washer ................................................................................................... 4 4 ..................... 808489-002 .............................. Chain Anchor .......................................................................................... 2 5 ..................... 050001-027 .............................. Pin Split ................................................................................................... 4 6 ..................... 807962 ..................................... Chain Pin ................................................................................................ 4 7 ..................... 050001-017 .............................. Pin Split ................................................................................................... 8 8 ..................... 050006-040 .............................. Screw ...................................................................................................... 1 9 ..................... 810434 ..................................... Shaft ........................................................................................................ 1 10 .................... 807715 ..................................... Shim ........................................................................................................ 3 11 .................... 127513-001 .............................. Pulley Cable ............................................................................................ 1 12 .................... 050009-051 .............................. Washer ................................................................................................... 1 13 .................... 119655-001 .............................. Pulley Hose ............................................................................................. 2 14 .................... 806267 ..................................... Pulley Chain ............................................................................................ 2 15 .................... 050012-056 .............................. Ring Retaining ........................................................................................ 2 16 .................... 050007-038 .............................. Screw ...................................................................................................... 1 17 .................... 121623 ..................................... Pulley Hose ............................................................................................. 1 18 .................... 806991-001 .............................. Shaft ........................................................................................................ 1 19 .................... 808489-001 .............................. Chain Anchor .......................................................................................... 2 20 .................... 050008-068 .............................. Nut .......................................................................................................... 4 21 .................... 050001-027 .............................. Pin Split ................................................................................................... 2 22 .................... 808488-001 .............................. Chain Anchor .......................................................................................... 1 23 .................... 803539 ..................................... Chain Pin ................................................................................................ 2 24 .................... 050001-013 .............................. Pin Roll ................................................................................................... 4 25 .................... 808488-002 .............................. Chain Anchor .......................................................................................... 1 26 .................... 793069-*** ............................... Chain (see next page) ............................................................................. 1 27 .................... 792968-*** ............................... Chain (see next page) ............................................................................. 2 28 .................... 806994 ..................................... Washer ................................................................................................... 2 29 .................... 806996 ..................................... Washer ................................................................................................... 2 30 .................... 050009-025 .............................. Washer ................................................................................................... 2 31 .................... 810435 ..................................... Shaft ........................................................................................................ 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-7.6-2140

143

TT MAST 1.4t/1.6t & 2.0t Position 26

Position 27

Collapsed Height

793069-009

792968-002

2022mm

793069-010

792968-013

2172mm

793069-003

792968-019

2322mm

793069-004

792968-015

2472mm

793069-005

792968-020

2572mm

793069-006

792968-021

2772mm

793069-012

792968-022

2922mm

793069-007

792968-018

3042mm

793069-013

792968-023

3192mm

793069-014

792968-024

3347mm

793069-015

792968-025

3492mm

793069-016

792968-026

3692mm

793069-017

792968-027

3842mm

793069-018

792968-028

3952mm

793069-019

792968-029

4252mm

793069-020

792968-030

4452mm Tab012gb

MP-7.6-2140

M1.0-0000-000144 144

MP-ESR4500-GB 06/04 • Printed in Germany

Page intentionally left blank

Printed in Germany

145

TILT AND SIDESHIFT

M1498 MP-7.7-2140

M1.0-0000-000146 146

MP-ESR4500-GB 06/04 • Printed in Germany

TILT AND SIDESHIFT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806181-001 .............................. Tilt & Sideshift (1.4/1.6t-1285/1425mm,L.Width/Tilt 2°/4°) ....................... 1 807382-001 .............................. Tilt & Sideshift (1.4/1.6t-1575mm, Leg Width/Tilt 2°/4°) ........................... 1 808418-001 .............................. Tilt & Sideshift (1.4/1.6t-1285/1425mm,L.Width/Tilt 2°/2°) ....................... 1 1 ........................... 808521-001 .............................. Frame (only for 806181-001 & 808418-001) ...................................... 1 808521-002 .............................. Frame (only for 807382-001) ............................................................. 1 2 ........................... 808522-001 .............................. Sleeve Bearing .................................................................................. 2 3* .......................... 808523 ..................................... Groove Ring ...................................................................................... 2 4 ........................... 808524 ..................................... Washer .............................................................................................. 2 5* .......................... 808525 ..................................... Stripper .............................................................................................. 2 6 ........................... 808526-001 .............................. Piston Rod (only for 806181-001 & 808418-001) .............................. 2 808526-002 .............................. Piston Rod (only for 807382-001) ..................................................... 2 7 ........................... 808527 ..................................... Seal Ring ........................................................................................... 2 8 ........................... 808528 ..................................... Dowel ................................................................................................ 2 9 ..................... 060030-057 .............................. Shim ........................................................................................................ 6 10 .................... 060030-085 .............................. Shim ........................................................................................................ 6 11 .................... 813806-002 .............................. Roller ∅ 101,30mm ................................................................................. AR 813806-003 .............................. Roller ∅ 101,72mm ................................................................................. AR 813806-004 .............................. Roller ∅ 102,14mm ................................................................................. AR 12 .......................... 808529-001 .............................. Sliding Piece ...................................................................................... 5 13 .......................... 808522-002 .............................. Sleeve Bearing .................................................................................. 1 14 .......................... 808530 ..................................... Piston ................................................................................................ 1 15 .......................... 808543 ..................................... Cylinder (only for 806181-001 & 807382-001) ................................... 1 808562 ..................................... Cylinder (only for 808418-001) .......................................................... 1 16 .......................... 808529-002 .............................. Sliding Piece ...................................................................................... 1 17 .......................... 808532 ..................................... Spiral Fixing Pin ................................................................................ 2 18 .......................... 808533 ..................................... Hook .................................................................................................. 1 19 .......................... 808534-001 .............................. Screw ................................................................................................ 2 20 .......................... 808535-001 .............................. Fork Carriage (only for 806181-001 & 808418-001) .......................... 1 808535-002 .............................. Fork Carriage (only for 807382-001) ................................................. 1 21 .......................... 808536 ..................................... Greasing Nipples .............................................................................. 3 22 .......................... 808529-003 .............................. Sliding Piece ...................................................................................... 1 23 .......................... 808534-002 .............................. Screw ................................................................................................ 2 24 .......................... 808537 ..................................... Pipe (only for 806181-001 & 807382-001) ......................................... 3 808560 ..................................... Pipe (only for 808418-001) ................................................................ 3 25 .......................... 808534-003 .............................. Screw (only for 806181-001 & 807382-001) ...................................... 3 808561 ..................................... Screw (only for 808418-001) ............................................................. 3 26 .......................... 808538 ..................................... Quick Clutch ..................................................................................... 2 27 .......................... 808539 ..................................... Tension Device .................................................................................. 2 28 .......................... 808534-004 .............................. Screw ................................................................................................ 2 29 .................... 795534 ..................................... Shim ........................................................................................................ 6

* ........................... 808541 ..................................... Seal Kit (inclusive 3, 5) ...................................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-7.7-2140

147

TILT AND SIDESHIFT

M1500 MP-7.7-2140

M1.0-0000-000148 148

MP-ESR4500-GB 06/04 • Printed in Germany

TILT AND SIDESHIFT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806181-002 .............................. Tilt & Sideshift (2.0t-1285/1425mm Leg Width/Tilt 2°/4°) ......................... 1 807382-002 .............................. Tilt & Sideshift (2.0t-1575mm Leg Width/Tilt 2°/4°) .................................. 1 808418-002 .............................. Tilt & Sideshift (2.0t-1285/1425mm Leg Width/Tilt 2°/2°) ......................... 1 1 ........................... 808542-001 .............................. Frame (only for 806181-002 & 808418-002) ...................................... 1 808542-002 .............................. Frame (only for 807382-002) ............................................................. 1 2 ........................... 808522-001 .............................. Sleeve Bearing .................................................................................. 2 3* .......................... 808523 ..................................... Groove Ring ...................................................................................... 2 4 ........................... 808524 ..................................... Washer .............................................................................................. 2 5* .......................... 808525 ..................................... Stripper .............................................................................................. 2 6 ........................... 808526-001 .............................. Piston Rod (only for 806181-002 & 808418-002) .............................. 2 808526-002 .............................. Piston Rod (only for 807382-002) ..................................................... 2 7 ........................... 808527 ..................................... Seal Ring ........................................................................................... 2 8 ........................... 808528 ..................................... Dowel ................................................................................................ 2 9 ..................... 060030-057 .............................. Shim ........................................................................................................ 8 10 .................... 060030-085 .............................. Shim ........................................................................................................ 8 11 .................... 813806-002 .............................. Roller ∅ 101,30mm ................................................................................. AR 813806-003 .............................. Roller ∅ 101,72mm ................................................................................. AR 813806-004 .............................. Roller ∅ 102,14mm ................................................................................. AR 12 .......................... 808529-001 .............................. Sliding Piece ...................................................................................... 5 13 .......................... 808522-002 .............................. Sleeve Bearing .................................................................................. 1 14 .......................... 808530 ..................................... Piston ................................................................................................ 1 15 .......................... 808543 ..................................... Cylinder (only for 806181-002 & 807382-002) ................................... 1 808562 ..................................... Cylinder (only for 808418-002) .......................................................... 1 16 .......................... 808529-002 .............................. Sliding Piece ...................................................................................... 1 17 .......................... 808532 ..................................... Spiral Fixing Pin ................................................................................ 2 18 .......................... 808533 ..................................... Hook .................................................................................................. 1 19 .......................... 808534-001 .............................. Screw ................................................................................................ 2 20 .......................... 808535-001 .............................. Fork Carriage (only for 806181-002 & 808418-002) .......................... 1 808535-002 .............................. Fork Carriage (only for 807382-002) ................................................. 1 21 .......................... 808536 ..................................... Greasing Nipples .............................................................................. 3 22 .......................... 808529-003 .............................. Sliding Piece ...................................................................................... 1 23 .......................... 808534-002 .............................. Screw ................................................................................................ 2 24 .......................... 808537 ..................................... Pipe (only for 806181-002 & 807382-002) ......................................... 3 808560 ..................................... Pipe (only for 808418-002) ................................................................ 3 25 .......................... 808534-003 .............................. Screw (only for 806181-002 & 807382-002) ...................................... 3 808561 ..................................... Screw (only for 808418-002) ............................................................. 3 26 .................... 795534 ..................................... Shim ........................................................................................................ 8 27 .......................... 808538 ..................................... Quick Clutch ..................................................................................... 2 28 .......................... 808539 ..................................... Tension Device .................................................................................. 2 29 .......................... 808534-004 .............................. Screw ................................................................................................ 2 30 .................... 808729 ..................................... Shim ........................................................................................................ 3 31 .................... 808730 ..................................... Shim ........................................................................................................ 3 32 .................... 808731 ..................................... Shim ........................................................................................................ 3 33 .................... 808732 ..................................... Shim ........................................................................................................ 2 34 .................... 050003-020 .............................. Screw ...................................................................................................... 2 053050-006 .............................. Adhesive ................................................................................................. AR * ........................... 808541 ..................................... Seal Kit (inclusive 3, 5) ...................................................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-7.7-2140

149

TILT AND SIDESHIFT 30 29 28 30 26

25 D 23

24 21

27 C 22

A

15

B

4

18 Cylinder

15

18 3

15

1 2

18 Cylinder

6 20 7

19

13

14

10

5 B 17

12

11 A

16 9 C 8

18 15 D

MP-2140-092 MP-7.7-2140

M1.0-0000-000150 150

MP-ESR4500-GB 06/04 • Printed in Germany

TILT AND SIDESHIFT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 808943-001 .............................. Valve Block ............................................................................................. 1 808941-001 .............................. Check Valve ............................................................................................ 1 2 ..................... 808942-001 .............................. Plug ......................................................................................................... 2 3 ..................... 808941-002 .............................. Counter Balance Valve ............................................................................ 1 4 ..................... 808553-002 .............................. Valve Solenoid ........................................................................................ 1 808940-002 .............................. Coil Solenoid ........................................................................................... 1 808553-004 .............................. Kit Seal ................................................................................................... 1 5 ..................... 808553-002 .............................. Valve Solenoid ........................................................................................ 1 808940-001 .............................. Coil Solenoid ........................................................................................... 1 808553-004 .............................. Kit Seal ................................................................................................... 1 6 ..................... 064004-002 .............................. Adaptor ................................................................................................... 1 7 ..................... 064065-002 .............................. Elbow ...................................................................................................... 1 8 ..................... 808043 ..................................... Pipe ......................................................................................................... 1 9 ..................... 054176-001 .............................. Adaptor ................................................................................................... 1 10 .................... 064061-001 .............................. Elbow ...................................................................................................... 1 11 .................... 808042 ..................................... Pipe ......................................................................................................... 1 12 .................... 054188-001 .............................. Elbow ...................................................................................................... 1 13 .................... 807479 ..................................... Bracket ................................................................................................... 1 051051-004 .............................. Binder ..................................................................................................... 4 14 .................... 050006-025 .............................. Screw ...................................................................................................... 2 15 .................... 064061-004 .............................. Elbow ...................................................................................................... 4 16 .................... 808044 ..................................... Pipe ......................................................................................................... 1 17 .................... 808045 ..................................... Pipe ......................................................................................................... 1 18 .................... 064004-007 .............................. Adaptor ................................................................................................... 4 19 .................... 808974 ..................................... Pipe ......................................................................................................... 1 20 .................... 808975 ..................................... Pipe ......................................................................................................... 1 21 .................... 807871 ..................................... Clamp ...................................................................................................... 1 22 .................... 050005-058 .............................. Screw ...................................................................................................... 1 23 .................... 064091-006 .............................. Plug ......................................................................................................... 1 24 .................... 807449 ..................................... Adaptor ................................................................................................... 1 25 .................... 807476 ..................................... Adaptor ................................................................................................... 1 26 .................... 808886-001 .............................. Main Harness LS/FKS Assembly (inclusive 813419Pressure Sensor) .. 1 813419 ..................................... Pressure Sensor (LS) ....................................................................... 1 051051-009 .............................. Cable Tie ................................................................................................. 2 793288 ..................................... Clip .......................................................................................................... 1 050003-012 .............................. Screw ...................................................................................................... 1 27 .................... 792991 ..................................... Microswitch (FKS) .................................................................................. 1 803310 ..................................... Actuator .................................................................................................. 1 807481 ..................................... Bracket ................................................................................................... 1 050005-011 .............................. Screw ...................................................................................................... 2 807541 ..................................... Plate ........................................................................................................ 1 050006-001 .............................. Screw ...................................................................................................... 2 796231 ..................................... Cable Assembly (only for Freezer/Corrosion) ......................................... 1 794590-001 .............................. Cable (only for Freezer/Corrosion) .................................................... 1 796230 ..................................... Heater Bracket (only for Freezer/Corrosion) ..................................... 1 050004-042 .............................. Screw (only for Freezer/Corrosion) ................................................... 2 050008-011 .............................. Nut (only for Freezer/Corrosion) ....................................................... 2 28 .................... 807488 ..................................... Switch ..................................................................................................... 1 792882 ..................................... Pin Crimp ................................................................................................ 2 29 .................... 055058-001 .............................. Puffer ...................................................................................................... 2 050008-001 .............................. Nut .......................................................................................................... 4 30 .................... 807681 ..................................... Bracket ................................................................................................... 1 050009-008 .............................. Washer ................................................................................................... 2 050005-058 .............................. Screw ...................................................................................................... 2 807953 ..................................... Valve Block (inclusive 1-5) ..................................................................... 1 808080 ..................................... Valve Assembly (inclusive 1-7, 10, 14, 15, 18) ...................................... 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-7.7-2140

02 REV. 11/05

151

TILT AND SIDESHIFT 5th Function Valve 22

21

22

20

21

20

19 9

14

17

19

12 B 13

1 A

18

15

16

2

11

10

D

3 C 4 7

D B

A

5

5 8 6 5 C MP-7.7-2140

M1.0-0000-000152 152

MP-2140-065 MP-ESR4500-GB 06/04 • Printed in Germany

TILT AND SIDESHIFT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 064061-001 .............................. Adaptor ................................................................................................... 1 2 ..................... 064010-002 .............................. Branch Tee Coupling ............................................................................... 1 3 ..................... 808837 ..................................... Pipe ......................................................................................................... 1 4 ..................... 808838 ..................................... Pipe ......................................................................................................... 1 5* .................... 064061-002 .............................. Adaptor ................................................................................................... 3 6* .................... 054183-001 .............................. Adaptor ................................................................................................... 1 7* .................... 807403 ..................................... Valve Solenoid ........................................................................................ 1 8 ..................... 050007-012 .............................. Screw ...................................................................................................... 2 9 ..................... 808836 ..................................... Bracket ................................................................................................... 1 10 .................... 050008-015 .............................. Nut .......................................................................................................... 2 11 .................... 050006-025 .............................. Screw ...................................................................................................... 2 12 .................... 793288 ..................................... Clip .......................................................................................................... 1 13 .................... 050003-013 .............................. Screw ...................................................................................................... 1 14 .................... 050008-008 .............................. Nut .......................................................................................................... 1 15 .................... 808841 ..................................... Pipe ......................................................................................................... 1 16 .................... 808865 ..................................... Pipe ......................................................................................................... 1 17 .................... 808840 ..................................... Bracket ................................................................................................... 1 18 .................... 050006-032 .............................. Screw ...................................................................................................... 2 19 .................... 054176-001 .............................. Adaptor ................................................................................................... 2 20 .................... 054171-002 .............................. Adaptor ................................................................................................... 2 21 .................... 054184-002 .............................. Adaptor (only for Quick Release Coupling) ............................................. 2 22 .................... 054185-002 .............................. Adaptor (only for Quick Release Coupling) ............................................. 2

* ..................... 808849 ..................................... Valve Assembly (included 5,6,7) ............................................................. 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-7.7-2140

153

TILT AND SIDESHIFT 6th Function Valve

3

2 5 7

3

8 1

2 4 5 2 7 4 1 2

9

12 10

12 11 13 13

14 16

15

17 MP-2140-083 MP-7.7-2140

M1.0-0000-000154 154

MP-ESR4500-GB 06/04 • Printed in Germany

TILT AND SIDESHIFT INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 807403 ..................................... Valve Solenoid ........................................................................................ 2 2 ..................... 064061-002 .............................. Elbow ...................................................................................................... 4 3 ..................... 064004-003 .............................. Adaptor ................................................................................................... 2 4 ..................... 054183-001 .............................. Adaptor ................................................................................................... 2 5 ..................... 050007-011 .............................. Screw ...................................................................................................... 4 6 ..................... 796725 ..................................... Bracket ................................................................................................... 1 7 ..................... 050008-015 .............................. Nut .......................................................................................................... 6 8 ..................... 050006-024 .............................. Screw ...................................................................................................... 2 9 ..................... 796724 ..................................... Bracket ................................................................................................... 1 10 .................... 050009-018 .............................. Washer ................................................................................................... 2 11 .................... 050006-032 .............................. Screw ...................................................................................................... 2 12 .................... 796728 ..................................... T-Adaptor ................................................................................................ 2 13 .................... 064073-001 .............................. Adaptor ................................................................................................... 2 14 .................... 796727 ..................................... Pipe ......................................................................................................... 1 15 .................... 064061-001 .............................. Elbow ...................................................................................................... 1 16 .................... 796726 ..................................... Pipe ......................................................................................................... 1 17 .................... 064010-002 .............................. T-Adaptor ................................................................................................ 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-7.7-2140

155

LIFT BUFFER

M1631 MP-7.7-2140

M1.0-0000-000156 156

MP-ESR4500-GB 06/04 • Printed in Germany

LIFT BUFFER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 806251 ..................................... Bracket ................................................................................................... 1 2 ..................... 806259 ..................................... Bracket ................................................................................................... 1 3 ..................... 806178 ..................................... Rubber .................................................................................................... 2 4 ..................... 806177 ..................................... Plunger ................................................................................................... 2 5 ..................... 050000-056 .............................. Pin ........................................................................................................... 2 6 ..................... 124018 ..................................... Buffer ...................................................................................................... 2 7 ..................... 050005-022 .............................. Screw ...................................................................................................... 2 053050-006 .............................. Adhesive ................................................................................................. AR 8 ..................... 050006-074 .............................. Screw ...................................................................................................... 4

053002-001 .............................. Grease .................................................................................................... AR

806173 ..................................... Stopper (included 1, 3-7) ......................................................................... 1 806199 ..................................... Stopper (included 2-7) ............................................................................ 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-7.7-2140

01 REV. 05/05

157

FORK

2 4

3

1

5

MP-2140-051 MP-7.9-2140

M1.0-0000-000158 158

MP-ESR4500-GB 06/04 • Printed in Germany

FORK INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ........................................................................ Fork (see table) ....................................................................................... 2 2 ........................................................................ Handle Assembly (included 2-5) ............................................................. 2 3 ........................................................................ Spring Compression ............................................................................... 2 4 ........................................................................ Pin ........................................................................................................... 2 5 ........................................................................ Detent ..................................................................................................... 2

1,4t/1,6t Fork Widht 40mm 1000mm

1067mm

1150mm

1220mm

1500mm

1600mm

803991-003-01

803991-009-01

803991-012-01

803991-007-01

803991-011-01

803991-010-01 Tab004gb

2.0t Fork Width 45mm 1000mm

1067mm

1150mm

1220mm

1300mm

1500mm

1600mm

807596-001

807596-002

807596-003

807596-004

807596-007

807596-005

807596-006 Tab023gb

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-7.9-2140

01 REV. 05/05

159

LOAD BACKREST

2

1

2

MP-2140-050 MP-7.10-2140

M1.0-0000-000160 160

MP-ESR4500-GB 06/04 • Printed in Germany

LOAD BACKREST INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 806193-001 .............................. Load Backrest (Leg Width 1285/1425mm) .............................................. 1 806193-002 .............................. Load Backrest (Leg Width 1575mm) ....................................................... 1 2 ..................... 050003-050 .............................. Screw ...................................................................................................... 4 Option

Load Backrest (Leg Width 1285/1425mm) 800mm

900mm

1000mm

1100mm

1200mm

1300mm

1400mm

1500mm

1600mm

1700mm

796175-019 796175-001 796175-002 796175-003 796175-004 796175-005 796175-006 796175-007 796175-008 796175-009 Tab002gb Load Backrest (Leg Widht 1575mm) 800mm

900mm

1000mm

1100mm

1200mm

1300mm

1400mm

1500mm

1600mm

1700mm

796175-020 796175-010 796175-011 796175-012 796175-013 796175-014 796175-015 796175-016 796175-017 796175-018 Tab003gb

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-7.10-2140

161

YOKE

1 2 3

2

3

4

5

15 6

7 14

10

2

1

8 13

12

11

9 8 MP-2140-054 MP-7.11-2140

M1.0-0000-000162 162

MP-ESR4500-GB 06/04 • Printed in Germany

YOKE INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806269 ..................................... Yoke ........................................................................................................ 1 1 ........................... 050012-065 .............................. Circlip ................................................................................................ 2 2 ........................... 806171 ..................................... Washer .............................................................................................. 3 3 ........................... 119655-001 .............................. Pulley ................................................................................................ 2 4 ........................... 050012-009 .............................. Circlip ................................................................................................ 1 5 ........................... 806154 ..................................... Shaft .................................................................................................. 1 6 ........................... 050000-003 .............................. Pin ..................................................................................................... 1 7 ........................... 806253 ..................................... Yoke Bracket ..................................................................................... 1 8 ........................... 060030-085 .............................. Washer .............................................................................................. 2 9 ........................... 806155 ..................................... Pulley ................................................................................................ 1 10 .......................... 127513-001 .............................. Pulley ................................................................................................ 1 11 .......................... 103349 ..................................... Pulley ................................................................................................ 1 12 .......................... 050009-013 .............................. Washer .............................................................................................. 1 13 .......................... 050012-013 .............................. Circlip ................................................................................................ 1 14 .......................... 810283 ..................................... Plate .................................................................................................. 1 15 .......................... 050003-021 .............................. Screw ................................................................................................ 1

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-7.11-2140

163

Page intentionally left blank

Printed in Germany

M1.0-0000-000164 164

SECTION 8

Printed in Germany

165

LIFT CYLINDER 1.4t/1.6t

4

10

9 11

8

12

7

6

5

1

3

2

MP-2140-052 MP-8.1-2140

M1.0-0000-000166 166

MP-ESR4500-GB 06/04 • Printed in Germany

LIFT CYLINDER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806200-*** ............................... Lift Cylinder ø40 (1.4/1.6t) ....................................................................... 2 1 ........................... 806204-*** ................................ Cylinder Tube ..................................................................................... 2 2 ........................... 812305 ..................................... Guide Ring ........................................................................................ 2 3 ........................... 811833-001 .............................. Piston Button ..................................................................................... 2 4 ........................... 804722-*** ................................ Piston Rod ......................................................................................... 2 5 ........................... 812304 ..................................... Guide Ring ........................................................................................ 2 6 ........................... 804774 ..................................... O-Ring ............................................................................................... 2 7 ........................... 807748 ..................................... Backup Ring ...................................................................................... 2 8 ........................... 811832 ..................................... Cylinder Cap ..................................................................................... 2 9 ........................... 804761 ..................................... Seal ................................................................................................... 2 10 .......................... 804755 ..................................... Wiper ................................................................................................. 2 11 .......................... 054173 ..................................... Seal ................................................................................................... 2 12 .......................... 054172 ..................................... Bleed Screw ...................................................................................... 2

813783 ..................................... Seal Kits ............................................................................................ 1

Position 0

Position 1

Position 4

Collapsed Height

806200-001

806204-001

804722-011

2022mm

806200-002

806204-002

804722-012

2172mm

806200-003

806204-003

804722-013

2322mm

806200-004

806204-004

804722-014

2472mm

806200-005

806204-005

804722-015

2572mm

806200-006

806204-006

804722-016

2772mm

806200-007

806204-007

804722-017

2922mm

806200-008

806204-008

804722-018

3042mm

806200-009

806204-009

804722-019

3192mm

806200-010

806204-010

804722-020

3347mm

806200-011

806204-011

804722-021

3492mm

806200-012

806204-012

804722-022

3692mm

806200-013

806204-013

804722-023

3842mm

806200-014

806204-014

804722-024

3952mm Tab006gb

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-8.1-2140

167

LIFT CYLINDER 1.4t/1.6t

4

10

9 11

8

12

7

6

5

1

3

2

MP-2140-052 MP-8.1-2140

M1.0-0000-000166 166A

MP-ESR4500-GB 06/04 • Printed in Germany

LIFT CYLINDER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 815496-*** ............................... Lift Cylinder LH ø40 (1.4/1.6t) ................................................................. 1 815495-*** ............................... Lift Cylinder RH ø40 (1.4/1.6t) ................................................................ 1 1 ........................... 815500-*** ................................ Cylinder Tube LH ............................................................................... 1 815499-*** ................................ Cylinder Tube RH .............................................................................. 1 2 ........................... 812305 ..................................... Guide Ring ........................................................................................ 2 3 ........................... 811833-001 .............................. Piston Button ..................................................................................... 2 4 ........................... 804722-*** ................................ Piston Rod ......................................................................................... 2 5 ........................... 812304 ..................................... Guide Ring ........................................................................................ 2 6 ........................... 804774 ..................................... O-Ring ............................................................................................... 2 7 ........................... 807748 ..................................... Backup Ring ...................................................................................... 2 8 ........................... 811832 ..................................... Cylinder Cap ..................................................................................... 2 9 ........................... 804761 ..................................... Seal ................................................................................................... 2 10 .......................... 804755 ..................................... Wiper ................................................................................................. 2 11 .......................... 054173 ..................................... Seal ................................................................................................... 2 12 .......................... 054172 ..................................... Bleed Screw ...................................................................................... 2

813783 ..................................... Seal Kits ............................................................................................ 1

Position 0

Position 1

Position 4

Collapsed Height

LH / RH

LH / RH

---

---

815496-001 / 815495-001

815500-001 / 815499-001

804722-011

2022mm

815496-002 / 815495-002

815500-002 / 815499-002

804722-012

2172mm

815496-003 / 815495-003

815500-003 / 815499-003

804722-013

2322mm

815496-004 / 815495-004

815500-004 / 815499-004

804722-014

2472mm

815496-005 / 815495-005

815500-005 / 815499-005

804722-015

2572mm

815496-006 / 815495-006

815500-006 / 815499-006

804722-016

2772mm

815496-007 / 815495-007

815500-007 / 815499-007

804722-017

2922mm

815496-008 / 815495-008

815500-008 / 815499-008

804722-018

3042mm

815496-009 / 815495-009

815500-009 / 815499-009

804722-019

3192mm

815496-010 / 815495-010

815500-010 / 815499-010

804722-020

3347mm

815496-011 / 815495-011

815500-011 / 815499-011

804722-021

3492mm

815496-012 / 815495-012

815500-012 / 815499-012

804722-022

3692mm

815496-013 / 815495-013

815500-013 / 815499-013

804722-023

3842mm

815496-014 / 815495-014

815500-014 / 815499-014

804722-024

3952mm Tab024gb

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-8.1-2140

01 REV. 05/05

167A

LIFT CYLINDER 2.0t

4

10

9 11

8

12

7

6

5

1

3

2

MP-2140-052 MP-8.1-2140

M1.0-0000-000168 168

MP-ESR4500-GB 06/04 • Printed in Germany

LIFT CYLINDER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 806201-*** ............................... Lift Cylinder ø45 (2.0t) ............................................................................ 2 1 ........................... 806205-*** ................................ Cylinder Tube ..................................................................................... 2 2 ........................... 812309 ..................................... Guide Ring ........................................................................................ 2 3 ........................... 811833-002 .............................. Piston Button ..................................................................................... 2 4 ........................... 806208-*** ................................ Piston Rod ......................................................................................... 2 5 ........................... 812305 ..................................... Guide Ring ........................................................................................ 2 6 ........................... 806232 ..................................... O-Ring ............................................................................................... 2 7 ........................... 807749 ..................................... Backup Ring ...................................................................................... 2 8 ........................... 811835 ..................................... Cylinder Cap ..................................................................................... 2 9 ........................... 806224 ..................................... Seal ................................................................................................... 2 10 .......................... 806226 ..................................... Wiper ................................................................................................. 2 11 .......................... 054173 ..................................... Seal ................................................................................................... 2 12 .......................... 054172 ..................................... Bleed Screw ...................................................................................... 2

813784 ..................................... Seal Kits ............................................................................................ 1

Position 0

Position 1

Position 4

Bauhöhe

806201-001

806205-001

806208-001

2022mm

806201-002

806205-002

806208-002

2172mm

806201-004

806205-004

806208-004

2472mm

806201-006

806205-006

806208-006

2772mm

806201-007

806205-007

806208-007

2922mm

806201-008

806205-008

806208-008

3042mm

806201-010

806205-010

806208-010

3347mm

806201-012

806205-012

806208-012

3692mm

806201-013

806205-013

806208-013

3842mm

806201-014

806205-014

806208-014

3952mm

806201-015

806205-015

806208-015

4252mm

806201-016

806205-016

806208-016

4452mm Tab007d

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-8.1-2140

169

LIFT CYLINDER 2.0t

4

10

9 11

8

12

7

6

5

1

3

2

MP-2140-052 MP-8.1-2140

M1.0-0000-000168 168A

MP-ESR4500-GB 06/04 • Printed in Germany

LIFT CYLINDER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 815498-*** ............................... Lift Cylinder LH ø45 (2.0t) ....................................................................... 1 815497-*** ............................... Lift Cylinder RH ø45 (2.0t) ...................................................................... 1 1 ........................... 815502-*** ................................ Cylinder Tube LH ............................................................................... 1 815501-*** ................................ Cylinder Tube RH .............................................................................. 1 2 ........................... 812309 ..................................... Guide Ring ........................................................................................ 2 3 ........................... 811833-002 .............................. Piston Button ..................................................................................... 2 4 ........................... 806208-*** ................................ Piston Rod ......................................................................................... 2 5 ........................... 812305 ..................................... Guide Ring ........................................................................................ 2 6 ........................... 806232 ..................................... O-Ring ............................................................................................... 2 7 ........................... 807749 ..................................... Backup Ring ...................................................................................... 2 8 ........................... 811835 ..................................... Cylinder Cap ..................................................................................... 2 9 ........................... 806224 ..................................... Seal ................................................................................................... 2 10 .......................... 806226 ..................................... Wiper ................................................................................................. 2 11 .......................... 054173 ..................................... Seal ................................................................................................... 2 12 .......................... 054172 ..................................... Bleed Screw ...................................................................................... 2

813784 ..................................... Seal Kits ............................................................................................ 1

Position 0

Position 1

Position 4

Collapsed Height

LH / RH

LH / RH

---

---

815498-001 / 815497-001

815502-001 / 815501-001

806208-001

2022mm

815498-002 / 815497-002

815502-002 / 815501-002

806208-002

2172mm

815498-004 / 815497-004

815502-004 / 815501-004

806208-004

2472mm

815498-006 / 815497-006

815502-006 / 815501-006

806208-006

2772mm

815498-007 / 815497-007

815502-007 / 815501-007

806208-007

2922mm

815498-008 / 815497-008

815502-008 / 815501-008

806208-008

3042mm

815498-010 / 815497-010

815502-010 / 815501-010

806208-010

3347mm

815498-012 / 815497-012

815502-012 / 815501-012

806208-012

3692mm

815498-013 / 815497-013

815502-013 / 815501-013

806208-013

3842mm

815498-014 / 815497-014

815502-014 / 815501-014

806208-014

3952mm

815498-015 / 815497-015

815502-015 / 815501-015

806208-015

4252mm

815498-016 / 815497-016

815502-016 / 815501-016

806208-016

4452mm Tab025gb

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-8.1-2140

01 REV. 05/05

169A

FREE LIFT CYLINDER 1.4t/1.6t

14 8 13

16 15

12

11

10 7

9 6 1

5

4

3

2

MP-2140-053 MP-8.2-2140

M1.0-0000-000170 170

MP-ESR4500-GB 06/04 • Printed in Germany

FREE LIFT CYLINDER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 810047-*** ............................... Free Lift Cylinder ø56 (1.4/1.6t) ............................................................... 1 1 ........................... 810049-*** ................................ Cylinder Tube ..................................................................................... 1 2 ........................... 806990 ..................................... Hose Burst Valve .............................................................................. 1 3 ........................... 812307 ..................................... Guide Ring ........................................................................................ 1 4 ........................... 811833-003 .............................. Piston Button ..................................................................................... 1 5 ........................... 050012-066 .............................. Ring Retaining ................................................................................... 1 6 ........................... 806211 ..................................... Piston Shut Off .................................................................................. 1 7 ........................... 806212 ..................................... Spring ................................................................................................ 1 8 ........................... 806209-*** ................................ Piston Rod ......................................................................................... 1 9 ........................... 812306 ..................................... Guide Ring ........................................................................................ 1 10 .......................... 804776 ..................................... O-Ring ............................................................................................... 1 11 .......................... 807746 ..................................... Backup Ring ...................................................................................... 1 12 .......................... 811834 ..................................... Cylinder Cap ..................................................................................... 1 13 .......................... 804763 ..................................... Seal ................................................................................................... 1 14 .......................... 804757 ..................................... Wiper ................................................................................................. 1 15 .......................... 054173 ..................................... Seal ................................................................................................... 1 16 .......................... 054172 ..................................... Bleed Screw ...................................................................................... 1

813785 ..................................... Seal Kits ............................................................................................ 1

Position 0

Position 1

Position 8

Collapsed Height

810047-001

810049-001

806209-001

2022mm

810047-002

810049-002

806209-002

2172mm

810047-003

810049-003

806209-003

2322mm

810047-004

810049-004

806209-004

2472mm

810047-005

810049-005

806209-005

2572mm

810047-006

810049-006

806209-006

2772mm

810047-007

810049-007

806209-007

2922mm

810047-008

810049-008

806209-008

3042mm

810047-009

810049-009

806209-009

3192mm

810047-010

810049-010

806209-010

3347mm

810047-011

810049-011

806209-011

3492mm

810047-012

810049-012

806209-012

3692mm

810047-013

810049-013

806209-013

3842mm

810047-014

810049-014

806209-014

3952mm Tab008gb

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-8.2-2140

171

FREE LIFT CYLINDER 2.0t

14 8 13

16 15

12

11

10 7

9 6 1

5

4

3

2

MP-2140-053 MP-8.2-2140

M1.0-0000-000172 172

MP-ESR4500-GB 06/04 • Printed in Germany

FREE LIFT CYLINDER INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 ..................... 810048-*** ............................... Free Lift Cylinder ø65 (2.0t) ..................................................................... 1 1 ........................... 810050-*** ................................ Cylinder Tube ..................................................................................... 1 2 ........................... 806988 ..................................... Hose Burst Valve .............................................................................. 1 3 ........................... 812311 ..................................... Guide Ring ........................................................................................ 1 4 ........................... 811833-004 .............................. Piston Button ..................................................................................... 1 5 ........................... 050012-066 .............................. Ring Retaining ................................................................................... 1 6 ........................... 806211 ..................................... Piston Shut Off .................................................................................. 1 7 ........................... 806212 ..................................... Spring ................................................................................................ 1 8 ........................... 806221-*** ................................ Piston Rod ......................................................................................... 1 9 ........................... 812310 ..................................... Guide Ring ........................................................................................ 1 10 .......................... 806233 ..................................... O-Ring ............................................................................................... 1 11 .......................... 807747 ..................................... Backup Ring ...................................................................................... 1 12 .......................... 811836 ..................................... Cylinder Cap ..................................................................................... 1 13 .......................... 812303 ..................................... Seal ................................................................................................... 1 14 .......................... 806227 ..................................... Wiper ................................................................................................. 1 15 .......................... 054173 ..................................... Seal ................................................................................................... 1 16 .......................... 054172 ..................................... Bleed Screw ...................................................................................... 1

813786 ..................................... Seal Kits ............................................................................................ 1

Position 0

Position 1

Position 8

Collapsed Height

810048-001

810050-001

806221-001

2022mm

810048-002

810050-002

806221-002

2172mm

810048-004

810050-004

806221-004

2472mm

810048-006

810050-006

806221-006

2772mm

810048-007

810050-007

806221-007

2922mm

810048-008

810050-008

806221-008

3042mm

810048-010

810050-010

806221-010

3347mm

810048-012

810050-012

806221-012

3692mm

810048-013

810050-013

806221-013

3842mm

810048-014

810050-014

806221-014

3952mm

810048-015

810050-015

806221-015

4252mm

810048-016

810050-016

806221-016

4452mm Tab009gb

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-8.2-2140

173

CYLINDER REACH 20

19

18 3 17

2 1 17

3 4 5

21

7 6

8 9 10

22

11 12 13

21 14

17 15 16 17

18 19 20 MP-8.5-2140

M1.0-0000-000174 174

MP-2140-047 MP-ESR4500-GB 06/04 • Printed in Germany

CYLINDER REACH INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1* .................... 811185-001 .............................. Cylinder Tube (1.4t) ................................................................................. 1 811185-002 .............................. Cylinder Tube (1.6t-2.0t) .......................................................................... 1 2* .................... 807404 ..................................... Bearing ................................................................................................... 1 3* .................... 064061-002 .............................. Adaptor ................................................................................................... 2 4* .................... 812105 ..................................... Guide Ring .............................................................................................. 1 5* .................... 807355 ..................................... Piston Seal .............................................................................................. 1 6* .................... 812103 ..................................... Piston Rod .............................................................................................. 1 7* .................... 804774 ..................................... O-Ring .................................................................................................... 1 8* .................... 807748 ..................................... Backup Ring ........................................................................................... 1 9* .................... 807343 ..................................... Washer ................................................................................................... 1 10* ................... 812100 ..................................... End, Cap ................................................................................................. 1 11* ................... 812106 ..................................... Guide Ring .............................................................................................. 1 12* ................... 807356 ..................................... Rod Seal ................................................................................................. 1 13* ................... 807357 ..................................... Wiper ....................................................................................................... 1 14* ................... 807407 ..................................... Washer ................................................................................................... 1 15* ................... 050008-069 .............................. Nut .......................................................................................................... 1 16* ................... 806402 ..................................... Rod End .................................................................................................. 1 17 .................... 806429 ..................................... Washer ................................................................................................... 4 18 .................... 806427 ..................................... Pin ........................................................................................................... 2 19 .................... 792973 ..................................... Pin Split ................................................................................................... 2 20 .................... 050006-026 .............................. Screw ...................................................................................................... 2 21 .................... 806810 ..................................... O-Ring .................................................................................................... 2 22 .................... 812897-*** ............................... Spacer (see Table) .................................................................................. 1 815038-001 .............................. Seal Kit (included 4, 5, 7, 8, 11, 12, 13) ................................................... 1

* ..................... 811184-001 .............................. Cylinder Reach (1.4t/included 1-16) ....................................................... 1 811184-002 .............................. Cylinder Reach (1.6t-2.0t/included 1-16) ............................................... 1

Position 22

420Ah

560Ah

700Ah

820Ah

1.4t.

----

812897-001

812897-002

----

1.6t.

----

812897-003

812897-004

812897-005

2.0t.

N/A

812897-003

812897-004

812897-005 Tab001

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-8.5-2140

175

Page intentionally left blank

Printed in Germany

M1.0-0000-000176 176

SECTION 9

Printed in Germany

177

FREEZER CABIN 18

17 19

1

20

37

21

38

25

32 26 30

12 16 15 11 8 10 9

14 13

7 6 5

5

4

3

7

28 27 23

34 33 35 40

29 24

22

31

38

36

39

Door

2 40 MP-2140-106

MP-9.3-2140

M1.0-0000-000178 178

MP-ESR4500-GB 05/05 • Printed in Germany

FREEZER CABIN INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 808567 ..................................... Window (heated) ..................................................................................... 1 808568 ..................................... Heater 48V .............................................................................................. 1 808572 ..................................... Door Switch ............................................................................................ 1 2 ..................... 808575 ..................................... Handle .................................................................................................... 1 3 ..................... 819077 ..................................... Lever ....................................................................................................... 1 4 ..................... 050003-020 .............................. Screw ...................................................................................................... 1 5 ..................... 050003-011 .............................. Screw ...................................................................................................... 3 6 ..................... 816751 ..................................... Bracket ................................................................................................... 1 7 ..................... 050003-058 .............................. Screw ...................................................................................................... 3 8 ..................... 819076 ..................................... Handle .................................................................................................... 1 9 ..................... 050009-013 .............................. Washer ................................................................................................... 1 10 .................... 050010-015 .............................. Washer ................................................................................................... 1 11 .................... 050006-024 .............................. Screw ...................................................................................................... 1 12 .................... 816752 ..................................... Locking Wedge ....................................................................................... 1 13 .................... 816755 ..................................... Plate ........................................................................................................ 1 14 .................... 816756 ..................................... Washer ................................................................................................... 1 15 .................... 816754 ..................................... Bail .......................................................................................................... 1 16 .................... 816753 ..................................... Bolt .......................................................................................................... 1 17 .................... 808574 ..................................... Window (heated) ..................................................................................... 1 808557 ..................................... Rubber Seal ............................................................................................ 1 18 .................... 808555 ..................................... Window (no heated) ................................................................................ 1 808556 ..................................... Window (heated) ..................................................................................... 1 808557 ..................................... Rubber Seal ............................................................................................ 1 819078 ..................................... Windscreen Wiper Assembly (manual) ................................................... 1 819079 ..................................... Bearing .............................................................................................. 1 819080 ..................................... Wiper Arm ......................................................................................... 1 819081 ..................................... Wiper Blade ....................................................................................... 1 19 .................... 808573 ..................................... Window (heated) ..................................................................................... 1 808557 ..................................... Rubber Seal ............................................................................................ 1 808569 ..................................... Windscreen Wiper 12V ........................................................................... 1 20 .................... 808558 ..................................... Window (heated) ..................................................................................... 1 808557 ..................................... Rubber Seal ............................................................................................ 1 21 .................... 814738 ..................................... Bracket ................................................................................................... 1 22 .................... 050068-003 .............................. Nut .......................................................................................................... 4 23 .................... 050071-009 .............................. Screw ...................................................................................................... 1 24 .................... 811996-001 .............................. Relay Socket .......................................................................................... 1 25 .................... 814744 ..................................... Relay ....................................................................................................... 1 26 .................... 050008-010 .............................. Nut .......................................................................................................... 1 27 .................... 050004-024 .............................. Screw ...................................................................................................... 8 28 .................... 050009-004 .............................. Washer ................................................................................................... 8 29 .................... 814736 ..................................... Contactor ................................................................................................ 2 30 .................... 814740 ..................................... Terminal ................................................................................................... 1 31 .................... 050005-054 .............................. Screw ...................................................................................................... 2 32 .................... 050008-001 .............................. Nut .......................................................................................................... 2 33 .................... 050005-058 .............................. Screw ...................................................................................................... 1 34 .................... 814958 ..................................... Fuse Holder ............................................................................................ 1 35 .................... 814995-001 .............................. Fuse 30A ................................................................................................ 1 36 .................... 814995-002 .............................. Fuse 50A ................................................................................................ 1 37 .................... 050008-008 .............................. Nut .......................................................................................................... 1 38 .................... 050078-008 .............................. Blind Rivet Nut ........................................................................................ 4 39 .................... 814739 ..................................... Cover ...................................................................................................... 1 40 .................... 050071-020 .............................. Screw ...................................................................................................... 4 808559 ..................................... Door lock Assembly (included 2 -16) ...................................................... 1

not illustrated 814565-001 .............................. Loom ....................................................................................................... 1 814565-002 .............................. Loom ....................................................................................................... 1 814982 ..................................... T - Connector .......................................................................................... 1 Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 05/05 • Printed in Germany

MP-9.3-2140

02 REV. 02/06

179

Page intentionally left blank

Printed in Germany

M1.0-0000-000180 180

SECTION 10

Printed in Germany

181

LABELS AND DECALS 1

6

1

2

2

8

3 4

9

5

5

5

7

21 13 20 18 19

14 12 10

11

17

15

16

22

23 17

25

24

MP-2140-094 MP-10.9-2140

MP-ESR4500-GB 06/04 • Printed in Germany

01 REV. 05/05 M1.0-0000-000182 182

LABELS AND DECALS INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ..................... 106158-020 .............................. Decal Crown Heavy ................................................................................ 2 2 ..................... 069372-034 .............................. Decal Momentum .................................................................................... 2 3 ..................... 869009-*** ............................... Warning Stand On ................................................................................... 1 4 ..................... 869010-*** ............................... Warning Stand Under .............................................................................. 1 5 ..................... 106158-001 .............................. Decal Crown Heavy ................................................................................ 3 6 ..................... 069374-001 .............................. Decal crown.com .................................................................................... 1 7 ..................... 069372-033 .............................. Decal Momentum .................................................................................... 1 8 ..................... 869104-*** ............................... Warning Moving Mast .............................................................................. 1 9 ..................... 869004-*** ............................... Warning Moving Vehicle .......................................................................... 1 10 .................... 869005-*** ............................... Warning Rider Truck ................................................................................ 1 11 .................... 869012-*** ............................... Warning Electrical Additions .................................................................... 1 12 .................... 069154 ..................................... Label Hydraulic Oil .................................................................................. 1 13 .................... 869314-*** ............................... Label Serial Number ................................................................................ 1 14 .................... 869502-*** ............................... Label Capacity Data ................................................................................ 1 15 .................... 869020-*** ............................... Danger Battery ....................................................................................... 1 16 .................... 869047-*** ............................... Caution, Charger Hook Up ..................................................................... 1 17 .................... 869006-*** ............................... Warning Hands Off ................................................................................. 2 18 .................... 869519-006 .............................. Label Info Point ....................................................................................... 1 19 .................... 869518-006 .............................. Label Info Point ....................................................................................... 1 20 .................... 869522-006 .............................. Label Info Point ....................................................................................... 1 21 .................... 869516-006 .............................. Label Info Point ....................................................................................... 1 22 .................... 869517-006 .............................. Label Info Point ....................................................................................... 1 23 .................... 869523-006 .............................. Label Info Point ....................................................................................... 1 24 .................... 869520-006 .............................. Label Info Point ....................................................................................... 1 25 .................... 869521-006 .............................. Label Info Point ....................................................................................... 1

*** ................... xxxxxx-001 .............................. German xxxxxx-002 .............................. French xxxxxx-003 .............................. Spanish xxxxxx-004 .............................. Dutch xxxxxx-005 .............................. Italien xxxxxx-006 .............................. English xxxxxx-010 .............................. Portoguese

Always Specify Model & Serial Number To select part number, refer to truck data number.

See Section ITD MP-ESR4500-GB 06/04 • Printed in Germany

MP-10.9-2140

02 REV. 11/05

183

Page intentionally left blank

Printed in Germany

M1.0-0000-000184 184